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Abstract:

The present disclosure relates to an electronic smoking article that
provides for improved aerosol delivery. Particularly, the article
comprises a wicking element useful for improving delivery of aerosol
precursor to a heating element. In particular, the wick can take on a
brush-like configuration. The present disclosure further relates to
methods of forming an aerosol in a smoking article.

Claims:

1-43. (canceled)

44. A method of forming an aerosol in a smoking article, the method
comprising initiating current flow from an electrical power source within
the smoking article to a resistance heating wire within the smoking
article, the heating wire being intertwined with a wick formed of a
plurality of individual filaments aligned in a brush-like configuration
so as to cause heating of the heating wire and vaporization of an aerosol
precursor composition transported by the wick.

45. The method of claim 44, wherein the smoking article comprises a
plurality of heating wires.

46. The method of claim 45, wherein two or more of the heating wires are
simultaneously heated.

47. The method of claim 46, wherein the aerosol precursor composition
comprises two or more separate components, and wherein the separate
components of the aerosol precursor composition are separately heated by
the simultaneously heated heating wires.

48. The method of claim 46, wherein the simultaneously heated heating
wires receive current flow from the electrical power source under
different conditions such that the heating wires are heated to different
temperatures or are heated for different amounts of time.

49. The method of claim 45, wherein two or more of the heating wires are
heated in a defined sequence or pattern.

50. A method of forming an aerosol in a smoking article, the method
comprising initiating current flow from an electrical power source within
the smoking article to a resistance heating wire within the smoking
article, the heating wire being intertwined with a wick formed of a
plurality of individual filaments aligned in a brush-like configuration,
the individual filaments each comprising an affixed end and a free end,
so as to cause heating of the heating wire and vaporization of an aerosol
precursor composition transported by the wick; wherein the smoking
article comprises a central axis extending the length of the smoking
article and an exterior shell wall, and the wick is positioned within the
smoking article such that the aerosol precursor composition is
transported outward from the central axis toward the exterior shell wall
or is transported inward, relative to the exterior shell wall, toward the
central axis.

51. The method of claim 50, wherein the filaments are axially aligned
along a length of the hollow shell.

52. The method of claim 50, wherein the axial alignment is substantially
a straight line or wherein the axial alignment is substantially helical.

53. The method of claim 50, wherein the heating wire is woven into the
filaments of the wick.

54. The method of claim 50, wherein the heater comprises a plurality of
resistance heating wires.

56. The method of claim 54, wherein the aerosol precursor composition
comprises two or more separate components, and wherein the separate
components of the aerosol precursor composition are separately heated by
the simultaneously heated heating wires.

57. The method of claim 54, wherein the simultaneously heated heating
wires receive current flow from the electrical power source under
different conditions such that the heating wires are heated to different
temperatures or are heated for different amounts of time.

58. The method of claim 54, wherein two or more of the heating wires are
heated in a defined sequence or pattern.

Description:

FIELD OF THE INVENTION

[0001] The present invention relates to aerosol delivery articles and uses
thereof for yielding tobacco components or other materials in an
inhalable form. The articles may be made or derived from tobacco or
otherwise incorporate tobacco for human consumption.

BACKGROUND OF THE INVENTION

[0002] Many smoking articles have been proposed through the years as
improvements upon, or alternatives to, smoking products based upon
combusting tobacco. Exemplary alternatives have included devices wherein
a solid or liquid fuel is combusted to transfer heat to tobacco or
wherein a chemical reaction is used to provide such heat source. Numerous
references have proposed various smoking articles of a type that generate
flavored vapor, visible aerosol, or a mixture of flavored vapor and
visible aerosol. Some of those proposed types of smoking articles include
tubular sections or longitudinally extending air passageways.

[0003] The point of the improvements or alternatives to smoking articles
typically has been to provide the sensations associated with cigarette,
cigar, or pipe smoking, without delivering considerable quantities of
incomplete combustion and pyrolysis products. To this end, there have
been proposed numerous smoking products, flavor generators, and medicinal
inhalers which utilize electrical energy to vaporize or heat a volatile
material, or attempt to provide the sensations of cigarette, cigar, or
pipe smoking without burning tobacco.

[0004] General examples of alternative smoking articles are described in
U.S. Pat. No. 3,258,015 to Ellis et al.; U.S. Pat. No. 3,356,094 to Ellis
et al.; U.S. Pat. No. 3,516,417 to Moses; U.S. Pat. No. 4,347,855 to
Lanzellotti et al.; U.S. Pat. No. 4,340,072 to Bolt et al.; U.S. Pat. No.
4,391,285 to Burnett et al.; U.S. Pat. No. 4,917,121 to Riehl et al.;
U.S. Pat. No. 4,924,886 to Litzinger; and U.S. Pat. No. 5,060,676 to
Hearn et al. Many of those types of smoking articles have employed a
combustible fuel source that is burned to provide an aerosol and/or to
heat an aerosol-forming material. See, for example, the background art
cited in U.S. Pat. No. 4,714,082 to Banerjee et al. and U.S. Pat. No.
4,771,795 to White et al.; which are incorporated herein by reference in
their entireties. See, also, for example, those types of smoking articles
described in U.S. Pat. No. 4,756,318 to Clearman et al.; U.S. Pat. No.
4,714,082 to Banerjee et al.; U.S. Pat. No. 4,771,795 to White et al.;
U.S. Pat. No. 4,793,365 to Sensabaugh et al.; U.S. Pat. No. 4,917,128 to
Clearman et al.; U.S. Pat. No. 4,961,438 to Korte; U.S. Pat. No.
4,966,171 to Serrano et al.; U.S. Pat. No. 4,969,476 to Bale et al.; U.S.
Pat. No. 4,991,606 to Serrano et al.; U.S. Pat. No. 5,020,548 to Fanier
et al.; U.S. Pat. No. 5,033,483 to Clearman et al.; U.S. Pat. No.
5,040,551 to Schlatter et al.; U.S. Pat. No. 5,050,621 to Creighton et
al.; U.S. Pat. No. 5,065,776 to Lawson; U.S. Pat. No. 5,076,296 to
Nystrom et al.; U.S. Pat. No. 5,076,297 to Farrier et al.; U.S. Pat. No.
5,099,861 to Clearman et al.; U.S. Pat. No. 5,105,835 to Drewett et al.;
U.S. Pat. No. 5,105,837 to Barnes et al.; U.S. Pat. No. 5,115,820 to
Hauser et al.; U.S. Pat. No. 5,148,821 to Best et al.; U.S. Pat. No.
5,159,940 to Hayward et al.; U.S. Pat. No. 5,178,167 to Riggs et al.;
U.S. Pat. No. 5,183,062 to Clearman et al.; U.S. Pat. No. 5,211,684 to
Shannon et al.; U.S. Pat. No. 5,240,014 to Deevi et al.; U.S. Pat. No.
5,240,016 to Nichols et al.; U.S. Pat. No. 5,345,955 to Clearman et al.;
U.S. Pat. No. 5,551,451 to Riggs et al.; U.S. Pat. No. 5,595,577 to
Bensalem et al.; U.S. Pat. No. 5,819,751 to Barnes et al.; U.S. Pat. No.
6,089,857 to Matsuura et al.; U.S. Pat. No. 6,095,152 to Beven et al;
U.S. Pat. No. 6,578,584 Beven; and U.S. Pat. No. 6,730,832 to Dominguez;
which are incorporated herein by reference in their entireties.
Furthermore, certain types of cigarettes that employ carbonaceous fuel
elements have been commercially marketed under the brand names "Premier"
and "Eclipse" by R. J. Reynolds Tobacco Company. See, for example, those
types of cigarettes described in Chemical and Biological Studies on New
Cigarette Prototypes that Heat Instead of Burn Tobacco, R. J. Reynolds
Tobacco Company Monograph (1988) and Inhalation Toxicology, 12:5, p. 1-58
(2000). See also US Pat. Pub. No. 2005/0274390 to Banerjee et al., US
Pat. Pub. No. 2007/0215167 to Crooks et al., US Pat. Pub. No.
2010/0065075 to Banerjee et al., and US Pat. Pub. No. 2012/0042885 to
Stone et al., the disclosures of which are incorporated herein by
reference in their entireties.

[0005] Certain proposed cigarette-shaped tobacco products purportedly
employ tobacco in a form that is not intended to be burned to any
significant degree. See, for example, U.S. Pat. No. 4,836,225 to Sudoh;
U.S. Pat. No. 4,972,855 to Kuriyama et al.; and U.S. Pat. No. 5,293,883
to Edwards, which are incorporated herein by reference in their
entireties. Yet other types of smoking articles, such as those types of
smoking articles that generate flavored vapors by subjecting tobacco or
processed tobaccos to heat produced from chemical or electrical heat
sources, are described in U.S. Pat. No. 4,848,374 to Chard et al.; U.S.
Pat. Nos. 4,947,874 and 4,947,875 to Brooks et al.; U.S. Pat. No.
5,060,671 to Counts et al.; U.S. Pat. No. 5,146,934 to Deevi et al.; U.S.
Pat. No. 5,224,498 to Deevi; U.S. Pat. No. 5,285,798 to Banerjee et al.;
U.S. Pat. No. 5,357,984 to Farrier et al.; U.S. Pat. No. 5,593,792 to
Farrier et al.; U.S. Pat. No. 5,369,723 to Counts; U.S. Pat. No.
5,692,525 to Counts et al.; U.S. Pat. No. 5,865,185 to Collins et al.;
U.S. Pat. No. 5,878,752 to Adams et al.; U.S. Pat. No. 5,880,439 to Deevi
et al.; U.S. Pat. No. 5,915,387 to Baggett et al.; U.S. Pat. No.
5,934,289 to Watkins et al.; U.S. Pat. No. 6,033,623 to Deevi et al.;
U.S. Pat. No. 6,053,176 to Adams et al.; U.S. Pat. No. 6,164,287 to
White; U.S. Pat. No. 6,289,898 to Fournier et al.; U.S. Pat. No.
6,615,840 to Fournier et al.; U.S. Pat. Pub. No. 2003/0131859 to Li et
al.; U.S. Pat. Pub. No. 2005/0016549 to Banerjee et al.; and U.S. Pat.
Pub. No. 2006/0185687 to Hearn et al., each of which is incorporated
herein by reference in its entirety.

[0006] Certain attempts have been made to deliver vapors, sprays or
aerosols, such as those possessing or incorporating flavors and/or
nicotine. See, for example, the types of devices set forth in U.S. Pat.
Nos. 4,190,046 to Virag; 4,284,089 to Ray; 4,635,651 to Jacobs; 4,735,217
to Gerth et al.; 4,800,903 to Ray et al.; 5,388,574 to Ingebrethsen et
al.; 5,799,663 to Gross et al.; 6,532,965 to Abhulimen et al.; and
6,598,607 to Adiga et al; and EP 1,618,803 to Hon; which are incorporated
herein by reference in their entireties. See also, U.S. Pat. No.
7,117,867 to Cox et al. and the devices set forth on the website,
www.e-cig.com, which are incorporated herein by reference in their
entireties.

[0007] Still further representative cigarettes or smoking articles that
have been described and, in some instances, been made commercially
available include those described in U.S. Pat No.

[0009] Smoking articles that employ tobacco substitute materials and
smoking articles that employ sources of heat other than burning tobacco
cut filler to produce tobacco-flavored vapors or tobacco-flavored visible
aerosols have not received widespread commercial success. Articles that
produce the taste and sensation of smoking by electrically heating
tobacco particularly have suffered from inconsistent release of flavors
or other inhalable materials. Electrically heated smoking devices have
further been limited in many instances to the requirement of an external
heating device that was inconvenient and that detracted from the smoking
experience. Accordingly, it can be desirable to provide a smoking article
that can provide the sensations of cigarette, cigar, or pipe smoking,
that does so without significantly combusting tobacco, that does so
without the need of a combustion heat source, and that does so without
necessarily delivering considerable quantities of incomplete combustion
and pyrolysis products.

BRIEF SUMMARY OF THE INVENTION

[0010] The present invention provides a smoking article and methods of use
thereof for controllably delivering aerosol precursor components. In
particular, disclosed herein is an article that incorporates one or more
wicks for use in vaporizing or aerosolizing a composition to provide a
desired result to a consumer of the article. Such result can be to
achieve an experience substantially similar to the smoking of a
conventional cigarette or to achieve delivery of a flavor or the like.

[0011] In various embodiments, a smoking article according to the present
disclosure can comprise a wick formed of a plurality of individual
filaments aligned in a brush-like configuration. More particularly, the
individual filaments of the wick each can comprise a first end that is
affixed to a holding member and an opposing free end.

[0012] In addition to the wick, the smoking article can further include a
hollow shell having the filaments of the wick positioned therein. For
example, the hollow shell can be the outer shell of a cartridge. In
certain embodiments, the filaments can be positioned within the hollow
shell such that the free ends of the filaments are directed toward an
interior of the hollow shell. More particularly, the filaments can be
circumferentially positioned around a segment of an interior surface of
the hollow shell (i.e., along portion of the length of the shell or along
the entire length of the shell). The filaments can form substantially a
single, uniform wick. In other embodiments, the filaments can form a
plurality of separate wick in that the filaments can be characterized as
being circumferentially positioned around a plurality of segments of the
interior surface of the hollow shell. Thus, a series of separate wicks
can be positioned along a length of the hollow shell, the filaments of
the wicks having free ends that are directed toward an interior of the
hollow shell. In addition to circumferential alignments, the filaments
can be axially aligned along a length of the hollow shell. Such axial
alignment can be substantially a straight line. Alternatively, the axial
alignment can be substantially helical or any further alignment that does
not substantially define a straight line. The filaments of the wicks can
be randomly attached to the holding member or can be specifically
patterned. In certain embodiments, the filaments can be aligned in a
plurality of rows.

[0013] In further embodiments, the filaments of the wick can be positioned
about a central axis of the hollow shell such that the free ends of the
filaments are directed outward toward an outer wall of the hollow shell.
In such embodiments, the smoking article further can comprise a central
member extending along the central axis through at least a portion of the
length of the hollow shell. The central member can be a reservoir and/or
a holding member for the filaments. In certain embodiments, the filaments
can be circumferentially positioned around a segment of the central
member. Again, in some embodiments, the filaments can be
circumferentially positioned around a plurality of segments of the
central member. The width of the segment where the wick is present can
vary, and wicks of different widths can be used in the same article. In
still further embodiments, the filaments of the wick can be axially
aligned along a length of the central member. Similar to the inwardly
wicking wick, the axial alignment of the outwardly wicking wicks can
vary. Specifically, the axial alignment can be substantially a straight
line. Alternatively, the axial alignment can be substantially helical,
and other non-straight alignments are also encompassed. In some
embodiments, the filaments can be aligned in a plurality of rows.
Although outwardly wicking wicks have been defined separately from the
inwardly wicking wicks, it is understood that any combination of the
various inwardly and outwardly wicking wicks can be used in a single
smoking article.

[0014] The physical orientation of the filaments in the wicks can vary. In
some embodiments, the filaments in a single wick can be substantially
uniform in length. In other embodiments, the filaments of a single wick
can be variable in length. When varying lengths are used, the filament
lengths can define a specific pattern.

[0015] In addition to the wick, the hollow shell of the smoking article
further can include an aerosol precursor composition. Preferably, the
wick can be operatively positioned within the smoking article to be
substantially in contact with the aerosol precursor composition (i.e.,
the filaments of the wicks being in fluid connection with the aerosol
precursor composition). The aerosol precursor composition can be in the
form of a liquid or gel at ambient conditions.

[0016] In some embodiments, the holding member to which the ends of the
filaments are connected can be a reservoir, and the aerosol precursor
composition can be retained by the reservoir. Thus, the filaments can be
in direct contact with the reservoir. The reservoir and the wick can be
present along only a segment of the hollow shell or can be present along
the entire length of the hollow shell. If desired, a plurality of
reservoirs can be used, and the reservoirs can be provided along a
plurality of segments of the hollow shell, each segment having a defined
width. Individual wicks then can be combined with the plurality of
reservoirs. Alternatively, a single reservoir can be used, and a
plurality of separate wicks can be present on a plurality of different
segments of the reservoir.

[0017] In other embodiments, the holding member to which the ends of the
filaments are connected can be distinct from the reservoir. In such
embodiments, the smoking article thus can include an aerosol precursor
composition retained by a reservoir and also can include a holding member
to which the filaments are connected. Preferably, the holding member can
be oriented relative to the reservoir such that the filaments of the wick
are in fluid connection with the reservoir. In some embodiments, such can
be achieved by embedding the holding member within the reservoir. More
complex arrangements also are encompassed. For example, the holding
member can be a hollow member, and the filaments can extend through an
outer wall of the hollow holding member and into the hollow interior. The
hollow holding member then can be connected to the reservoir, such as via
appropriate tubing, such that liquid aerosol precursor composition from
the reservoir can be transported to the hollow holding member to be
transported by the filaments out of the hollow holding member. If desired
active pumping of the liquid can be used, or one or more valves can be
utilized to control flow of the liquid from the reservoir to the holding
member.

[0018] The smoking article of the present disclosure further can include a
heater. In specific embodiments, the heater can be a resistance heating
wire. Such heating wire can be arranged with the filaments of the wick so
as to provide for controlled heating of the aerosol precursor composition
transported by the filaments. For example, the heating wire can be at
least partially intertwined with the filaments of the wick. In some
embodiments, the heating wire can actually be woven into the filaments of
the wick. Machine weaving techniques can be used to weave the heating
wire into the filaments. If desired, a single heating wire can be used
and can be intertwined with the filaments randomly or in a defined
pattern such that the desired heating of the filaments can be achieved.
In other embodiments, the heater can comprise a plurality of resistance
heating wires. Two or more heating wires thus can be intertwined with the
filaments of a single wick. Alternatively, different heating wires can be
intertwined with the filaments of the wick. For example, a first heater
wire can be in contact with a first segment of the wick, and a second
heater wire can be in contact with a second segment of the wick.
Similarly, a first heater wire can be in contact with a first set of
filaments, and a second heater wire can be in contact with a second set
of filaments. Thus, the different heating wires can be used with a single
wick or can be used with different wicks. This can be beneficial to
provide for controlled aerosol composition and delivery. For example, a
first set of filaments (e.g., a specific wick or a specific segment of a
wick) can be adapted to transport a first aerosol precursor material and
a second set of filaments (e.g., a specific wick or a specific segment of
a wick) can be adapted to transport a second aerosol precursor material.
This can be accomplished, for example, by segmenting a single reservoir
such that different aerosol precursor materials are stored in separate
segments of the reservoir or by providing a plurality of separate
reservoirs in fluid connection with different sets of filaments or
different wicks.

[0019] When utilizing a plurality of heating wires, the first heater wire
and the second heater wire can provide differing heating modes. For
example, a control component of the smoking article can be adapted to
deliver electrical current to the wire in a manner such that the heating
mode can be defined by one or more of heating temperature, heating rate,
and total heating time.

[0020] From the above, it can be seen that the present disclosure provides
a variety of wick designs that are adapted to achieve specific transport
of an aerosol precursor composition. In some embodiments, a smoking
article according to the disclosure can comprise a wick positioned within
a hollow shell so as to transport an aerosol precursor material inward
from an exterior wall of the hollow shell toward a central axis extending
the length of the hollow shell. In other embodiments, a smoking article
can comprise a wick positioned within a hollow shell so as to transport
an aerosol precursor material outward from a central axis extending the
length of the hollow shell toward an exterior wall of the hollow shell.
The smoking article also can include a variety of further components such
as an electrical power source and a control component, such as a
puff-actuated sensor or a capacitive sensor.

[0021] In further embodiments, the present disclosure also encompasses
methods of forming an aerosol in a smoking article. Specifically, the
method can comprise initiating current flow from an electrical power
source within the smoking article to a resistance heating wire within the
smoking article, the heating wire being intertwined with a wick fowled of
a plurality of individual filaments aligned in a brush-like configuration
so as to cause heating of the heating wire and an aerosol precursor
composition transported by the wick. The smoking article can comprise a
single heating wire of a plurality of heating wires. For example, two or
more of the heating wires can be simultaneously heated to heat a single
wick or a plurality of wicks. More specifically, the smoking article can
be adapted to separately heat two or more separate components of the
aerosol precursor composition utilizing two or more separate heating
wires, which can be separately or simultaneously heated. When
simultaneously heated, the heating wires can receive current flow from
the electrical power source under different conditions such that the
heating wires are heated to different temperatures or are heated for
different amounts of time. Alternatively, two or more of the heating
wires can be heated in a defined sequence or pattern.

BRIEF DESCRIPTION OF THE FIGURES

[0022] Having thus described the invention in the foregoing general terms,
reference will now be made to the accompanying drawings, which are not
necessarily drawn to scale, and wherein:

[0023] FIG. 1 is a perspective view of an example embodiment of a smoking
article according to the disclosure, wherein a portion of an outer shell
of the article is cut away to reveal the interior components thereof;

[0024] FIG. 2 is a perspective view of an example embodiment of a smoking
article according to the disclosure, wherein the article comprises a
control body and a cartridge that are attachable and detachable
therefrom;

[0025] FIG. 3 is a cross-section of an example embodiment of a smoking
article according to the disclosure showing a heating element in contact
with a wick formed of a plurality of filaments circumferentially
positioned around a segment of an interior surface of a hollow shell of a
smoking article;

[0026] FIG. 4 is a perspective view of an example embodiment of a smoking
article according to the disclosure showing a partially cut away shell
revealing therein a plurality of reservoirs with circumferentially
aligned filaments forming an inwardly wicking wick attached thereto;

[0027] FIG. 5 is a perspective view of an example embodiment of a smoking
article according to the disclosure showing a hollow shell with a
partially transparent outer wall and having therein a plurality of
axially aligned wicks formed of a plurality of individual filaments in an
inwardly wicking configuration, the wicks being in fluid communication
with a reservoir;

[0028] FIG. 6 is a cross-section of an example embodiment of a smoking
article according to the disclosure showing a reservoir around the
interior circumference of a hollow shell, the reservoir having a
plurality of wicks in fluid connection therewith, the wicks being formed
of a plurality of individual filaments that are connected to a holding
member at a first end and that have a second, free end aligned in an
inwardly wicking configuration;

[0029] FIG. 7 is a perspective view of an example embodiment of a smoking
article according to the disclosure showing a hollow shell with a
partially transparent outer wall, the hollow shell having therein a
helical, axially aligned reservoir having a plurality of individual
filaments in a fluid connection therewith forming an inwardly wicking
wick;

[0030] FIG. 8 is a cross-section of an example embodiment of a smoking
article according to the disclosure showing a central member within a
hollow shell, the central member functioning as a reservoir and having a
plurality of wicks in fluid connection therewith, the wicks being foamed
of a plurality of individual filaments that are connected to the holding
member and that are aligned in an outwardly wicking configuration;

[0031] FIG. 9 is a cross-section of an example embodiment of a smoking
article according to the disclosure showing a central member within a
hollow shell, the central member functioning as a reservoir and having a
plurality of wicks in fluid connection therewith, the wicks being formed
of a plurality of individual filaments that are connected to the central
member at a first end and that have a second, free end aligned in an
outwardly wicking configuration; and

[0032] FIG. 10 is a perspective view of an example embodiment of a smoking
article according to the disclosure showing a hollow shell with a
partially transparent outer wall and having therein a plurality of
axially aligned wicks formed of a plurality of individual filaments in an
outwardly wicking configuration, the wicks being in fluid connection with
a central member functioning as a reservoir.

DETAILED DESCRIPTION OF THE INVENTION

[0033] The present invention will now be described more fully hereinafter
with reference to exemplary embodiments thereof. These exemplary
embodiments are described so that this disclosure will be thorough and
complete, and will fully convey the scope of the invention to those
skilled in the art. Indeed, the invention may be embodied in many
different forms and should not be construed as limited to the embodiments
set forth herein; rather, these embodiments are provided so that this
disclosure will satisfy applicable legal requirements. As used in the
specification, and in the appended claims, the singular forms "a", "an",
"the", include plural referents unless the context clearly dictates
otherwise.

[0034] The present invention provides articles that use electrical energy
to heat a material (preferably without combusting the material to any
significant degree) to form an inhalable substance, the articles being
sufficiently compact to be considered "hand-held" devices. In certain
embodiments, the articles can particularly be characterized as smoking
articles. As used herein, the term is intended to mean an article that
provides the taste and/or the sensation (e.g., hand-feel or mouth-feel)
of smoking a cigarette, cigar, or pipe without substantial combustion of
any component of the article. The term smoking article does not
necessarily indicate that, in operation, the article produces smoke in
the sense of the by-product of combustion or pyrolysis. Rather, smoking
relates to the physical action of an individual in using the
article--e.g., holding the article, drawing on one end of the article,
and inhaling from the article. In further embodiments, the inventive
articles can be characterized as being vapor-producing articles,
aerosolization articles, or medicament delivery articles. Thus, the
articles can be arranged so as to provide one or more substances in an
inhalable state. In other embodiments, the inhalable substance can be
substantially in the form of a vapor (i.e., a substance that is in the
gas phase at a temperature lower than its critical point). In other
embodiments, the inhalable substance can be in the form of an aerosol
(i.e., a suspension of fine solid particles or liquid droplets in a gas).
The physical form of the inhalable substance is not necessarily limited
by the nature of the inventive articles but rather may depend upon the
nature of the medium and the inhalable substance itself as to whether it
exists in a vapor state or an aerosol state. In some embodiments, the
terms may be interchangeable. Thus, for simplicity, the terms as used to
describe the invention are understood to be interchangeable unless stated
otherwise.

[0035] In one aspect, the present invention provides a smoking article.
The smoking article generally can include a number of components provided
within an elongated body, which can be a single, unitary shell or which
can be formed of two or more separable pieces. For example, a smoking
article according to one embodiment can comprise a shell (i.e., the
elongated body) that can be substantially tubular in shape, such as
resembling the shape of a conventional cigarette or cigar. Within the
shell can reside all of the components of the smoking article (one or
more of which may be replaceable). In other embodiments, a smoking
article can comprise two shells that are joined and are separable. For
example, a control body can comprise a shell containing one or more
reusable components and having an end that removably attaches to a
cartridge. The cartridge can comprise a shell containing one or more
disposable components and having an end that removably attaches to the
control body. More specific arrangements of components within the single
shell or within the separable control body and cartridge are evident in
light of the further disclosure provided herein.

[0036] Smoking articles useful according to the invention particularly can
comprise some combination of a power source (i.e., an electrical power
source), one or more control components (e.g., to
control/actuate/regulate flow of power from the power source to one or
more further components of the article), a heater component, and an
aerosol precursor composition. The smoking article further can include a
defined air flow path through the article such that aerosol generated by
the article can be withdrawn therefrom by a user drawing on the article.
Alignment of the components within the article can vary. In specific
embodiments, the aerosol precursor composition can be located near an end
of the article that is proximal to the mouth of a user so as to maximize
aerosol delivery to the user. Other configurations, however, are not
excluded. Generally, the heater component can be positioned sufficiently
near the aerosol precursor composition so that heat from the heater
component can volatilize the aerosol precursor material (as well as one
or more flavorants, medicaments, or the like that may likewise be
provided for delivery to a user) and form an aerosol for delivery to the
user. When the heating member heats the aerosol precursor composition, an
aerosol (comprising one or more components of the aerosol precursor
composition) is formed, released, or generated in a physical form
suitable for inhalation by a consumer. It should be noted that the
foregoing teems are meant to be interchangeable. As such, the terms
release, generate, and form can be interchangeable, the terms releasing,
generating, and forming can be interchangeable, the terms releases,
forms, and generates can be interchangeable, and the terms released,
formed, and generated can be interchangeable. Specifically, one or more
components of the aerosol precursor composition is vaporized and mixed
with air to form an aerosol for inhalation by a user.

[0037] Referring now to FIG. 1, a smoking article 10 according to the
invention generally can comprise a shell 15 and a plurality of components
provided within the shell. The article can be characterized as having a
mouthend 11 (i.e., the end upon which a consumer can draw to inhale
aerosol from the article), and a distal end 12. The illustrated article
is provided as a single unitary device (however, line A indicates an
optional demarcation whereby the device can be two separate components
that are joined together, either removably or permanently, such as by
gluing). As will be evident from the further disclosure herein, it can be
preferable for further embodiments of the article to be formed of two or
more detachable units, each housing separate components of the article.
The various components shown in the embodiment of FIG. 1 can be present
in other embodiments, including embodiments formed of multiple units.

[0038] The article 10 according to the invention can have an overall shape
that may be defined as being substantially rod-like or substantially
tubular shaped or substantially cylindrically shaped. As illustrated in
FIG. 1, the article has a substantially round cross-section; however,
other cross-sectional shapes (e.g., oval, square, triangle, etc.) also
are encompassed by the present disclosure. Such language that is
descriptive of the physical shape of the article may also be applied to
the individual units of the article in embodiments comprising multiple
units, such as a control body and a cartridge.

[0039] The shell 15 of the smoking article 10 can be formed of any
material suitable for forming and maintaining an appropriate
conformation, such as a tubular shape, and for retaining therein the
suitable components of the article. The shell can be formed of a single
wall, as shown in FIG. 1. In some embodiments, the shell can be formed of
a material (natural or synthetic) that is heat resistant so as to retain
its structural integrity--e.g., does not degrade--at least at a
temperature that is the heating temperature provided by the resistive
heating element, as further discussed herein. In some embodiments, a heat
resistant polymer or a metal (e.g., stainless steel) may be used. In
other embodiments, the shell can be formed from paper, such as a paper
that is substantially straw-shaped. As further discussed herein, the
shell, such as a paper tube, may have one or more layers associated
therewith that function to substantially prevent movement of heat or
vapor therethrough. In one example, an aluminum foil layer may be
laminated to one surface of the shell. Ceramic materials also may be
used.

[0040] As seen in the embodiment of FIG. 1, the smoking article 10 can
include an electronic control component 20, a flow sensor 30, and a
battery 40, and these components can be placed in a variety of orders
within the article. Although not expressly shown, it is understood that
the article 10 can include wiring as necessary to provide power from the
battery 40 to the further components and to interconnect the components
for appropriate operation of the necessary functions provided by the
article.

[0041] The battery 40 is one example of an electrical power source (or
electrical power sources) that can be present to provide current flow
that is sufficient to provide various functionalities to the article,
such as powering of the heater elements, powering of indicators, powering
of internal circuitry, and the like. The power source can take on various
embodiments. Preferably, the power source is able to deliver sufficient
power to rapidly heat a resistive heater to provide for aerosol formation
and power the article through use for the desired duration of time. The
power source preferably is sized to fit conveniently within the article.
Examples of useful power sources include lithium ion batteries that
preferably are rechargeable (e.g., a rechargeable lithium-manganese
dioxide battery). In particular, lithium polymer batteries can be used.
Other types of batteries--e.g., N50-AAA CADNICA nickel-cadmium cells--may
also be used. Even further examples of batteries that can be used
according to the invention are described in US Pub. App. No.
2010/0028766, the disclosure of which is incorporated herein by reference
in its entirety. Thin film batteries may be used in certain embodiments
of the invention. Any of these batteries or combinations thereof can be
used in the power source, but rechargeable batteries are preferred
because of cost and disposal considerations associated with disposable
batteries. In embodiments wherein disposable batteries are provided, the
smoking article can include access for removal and replacement of the
battery. Alternatively, in embodiments where rechargeable batteries are
used, the smoking article can comprise charging contacts for interaction
with corresponding contacts in a conventional recharging unit deriving
power from a standard 120-volt AC wall outlet, or other sources such as
an automobile electrical system or a separate portable power supply,
including USB connections. Means for recharging the battery can be
provided in a portable charging case that can include, for example, a
relatively larger battery unit that can provide multiple charges for the
relatively smaller batteries present in the smoking article. The article
further can include components for providing a non-contact inductive
recharging system such that the article can be charged without being
physically connected to an external power source. Thus, the article can
include components to facilitate transfer of energy from an
electromagnetic field to the rechargeable battery within the article.

[0042] In further embodiments, the power source also can comprise a
capacitor. Capacitors are capable of discharging more quickly than
batteries and can be charged between puffs, allowing the battery to
discharge into the capacitor at a lower rate than if it were used to
power the heating member directly. For example, a supercapacitor--i.e.,
an electric double-layer capacitor (EDLC)--may be used separate from or
in combination with a battery. When used alone, the supercapacitor may be
recharged before each use of the article. Thus, the invention also may
include a charger component that can be attached to the smoking article
between uses to replenish the supercapacitor.

[0043] The smoking article can further include a variety of power
management software, hardware, and/or other electronic control
components. For example, such software, hardware, and/or electronic
controls can include carrying out charging of the battery, detecting the
battery charge and discharge status, performing power save operations,
preventing unintentional or over-discharge of the battery, puff counting,
puff delimiting, puff duration, identifying cartridge status, temperature
control, or the like. As such, the articles of the disclosure can include
one or more microchips or microcontrollers. Moreover, the articles can be
adapted for inclusion of programmable hardware that can be pre-programmed
and/or can be programmed post-market, such as via input of software or
other commands that can be downloaded by the hardware through an included
linking port (e.g., a USB port or similar port that can allow for
attachment of the article to a computer, smart phone, tablet, or the
like), or through a wireless communication component.

[0044] The control component 20 can encompass a variety of elements useful
in the present smoking article. Moreover, a smoking article according to
the invention can include one, two, or even more control components that
can be combined into a unitary element or that can be present at separate
locations within the smoking article, and individual control components
can be utilized for carrying out different control aspects. For example,
a smoking article can include a control component that is integral to or
otherwise combined with a battery so as to control power discharge from
the battery. The smoking article separately can include a control
component that controls other aspects of the article. The smoking article
also can include a control component in a cartridge for providing
specific functionalities, including data storage (e.g., a microchip that
includes memory). Such control component can include any hardware and/or
software elements as otherwise discussed herein.

[0045] Alternatively, a single controller may be provided that carries out
multiple control aspects or all control aspects of the article. Likewise,
a sensor 30 (e.g., a puff sensor) used in the article can include a
control component that controls the actuation of power discharge from the
power source in response to a stimulus. If desired, multiple controllers
and/or sensors can be used. The article separately can include a control
component that controls other aspects of the article. Specifically, a
single controller may be provided in or otherwise associated with the
sensor for carrying out multiple control aspects or all control aspects
of the article. Thus, a variety of combinations of controllers may be
combined in the present smoking article to provide the desired level of
control of all aspects of the device.

[0046] The smoking article also can comprise one or more controller
components useful for controlling flow of electrical energy from the
power source to further components of the article, such as to a resistive
heating element. Specifically, the article can comprise a control
component that actuates current flow from the power source, such as to
the resistive heating element. For example, in some embodiments, the
article can include a pushbutton that can be linked to a control circuit
for manual control of power flow. One or more pushbuttons present can be
substantially flush with an outer surface of the smoking article.

[0047] Instead of (or in addition to) the pushbutton, the inventive
article can include one or more control components or sensors responsive
to the consumer's drawing on the article (i.e., puff-actuated heating).
For example, the article may include a switch that is sensitive either to
pressure changes or air flow changes as the consumer draws on the article
(i.e., a puff-actuated switch). Other current actuation/deactuation
mechanisms may include a temperature actuated on/off switch or a lip
pressure actuated switch. An exemplary mechanism that can provide such
puff-actuation capability includes a Model 163PC01D36 silicon sensor,
manufactured by the MicroSwitch division of Honeywell, Inc., Freeport,
Ill. Further examples of demand-operated electrical switches that may be
employed in a heating circuit according to the present invention are
described in U.S. Pat. No. 4,735,217 to Gerth et al., which is
incorporated herein by reference in its entirety. Other suitable
differential switches, analog pressure sensors, flow rate sensors, or the
like, will be apparent to the skilled artisan with the knowledge of the
present disclosure. A pressure-sensing tube or other passage providing
fluid connection between the puff actuated switch and an air flow passage
within the smoking article can be included so that pressure changes
during draw are identified by the switch. Further description of current
regulating circuits and other control components, including
microcontrollers, that can be useful in the present smoking article are
provided in U.S. Pat. Nos. 4,922,901, 4,947,874, and 4,947,875, all to
Brooks et al., U.S. Pat. No. 5,372,148 to McCafferty et al., U.S. Pat.
No. 6,040,560 to Fleischhauer et al., and U.S. Pat. No. 7,040,314 to
Nguyen et al., all of which are incorporated herein by reference in their
entireties.

[0048] Capacitive sensing components in particular can be incorporated
into the device in a variety of manners to allow for diverse types of
"power-up" and/or "power-down" for one or more components of the device.
Capacitive sensing can include the use of any sensor incorporating
technology based on capacitive coupling including, but not limited to,
sensors that detect and/or measure proximity, position or displacement,
humidity, fluid level, pressure, temperature, or acceleration. Capacitive
sensing can arise from electronic components providing for surface
capacitance, projected capacitance, mutual capacitance, or self
capacitance. Capacitive sensors generally can detect anything that is
conductive or has a dielectric different than that of air. Capacitive
sensors, for example, can replace mechanical buttons (i.e., the
push-button referenced above) with capacitive alternatives. Thus, one
specific application of capacitive sensing according to the invention is
a touch capacitive sensor. For example, a touch pad can be present on the
smoking article that allows the user to input a variety of commands. Most
basically, the touch pad can provide for powering the heating element
much in the same manner as a push button, as already described above. In
other embodiments, capacitive sensing can be applied near the mouthend of
the smoking article such that the pressure of the lips on the smoking
article to draw on the article can signal the device to provide power to
the heating element. In addition to touch capacitance sensors, motion
capacitance sensors, liquid capacitance sensors, and accelerometers can
be utilized according to the invention to elicit a variety of response
from the smoking article. Further, photoelectric sensors also can be
incorporated into the inventive smoking article.

[0049] Sensors utilized in the present articles can expressly signal for
power flow to the heating element so as to heat the aerosol precursor
composition and form a vapor or aerosol for inhalation by a user. Sensors
also can provide further functions. For example, a "wake-up" sensor can
be included. Other sensing methods providing similar function likewise
can be utilized according to the invention.

[0050] Returning to FIG. 1, the article 10 can include a resistive heating
element 50. The resistive heating element can be electrically connected
to the battery 40 through appropriate wiring to facilitate formation of a
closed electrical circuit with current flowing through the resistive
heating element. Further wiring (not illustrated) can be included to
provide the necessary electrical connections within the article. In
specific embodiments, the article 10 can be wired with an electrical
circuit such that the control component 20 delivers, controls, or
otherwise modulates power from the battery 40 for energizing the
resistive heating element 50 according to one or more defined algorithms,
including pulse width modulation. Such electrical circuit can
specifically incorporate the flow sensor 30 such that the article 10 is
only active at times of use by the consumer. For example, when a consumer
puffs on the article 10, the flow sensor detects the puff, and the
control component 20 is then activated to direct power through the
article such that the resistive heating element 50 produces heat and thus
provides aerosol for inhalation by the consumer. The control algorithm
may call for power to the resistive heating element 50 to cycle and thus
maintain a defined temperature. The control algorithm therefore can be
programmed to automatically deactivate the article 10 and discontinue
power flow through the article after a defined time lapse without a puff
by a consumer. Moreover, the article can include a temperature sensor to
provide feedback to the control component. Such sensor can be, for
example, in direct contact with the resistive heating element 50.
Alternative temperature sensing means likewise can be used, such as
relying upon logic control components to evaluate resistance through the
resistive heating element and correlate such resistance to the
temperature of the element. In other embodiments, the flow sensor 30 can
be replaced by appropriate components to provide alternative sensing
means, such as capacitive sensing. Any variety of sensors and
combinations thereof can be incorporated, as described herein. Still
further, one or more control buttons 16 can be included to allow for
manual actuation by a consumer to elicit a variety of functions, such as
powering the article 10 on and off, turning on the resistive heating
element 50 to generate a vapor or aerosol for inhalation, or the like.

[0051] When the consumer draws on the mouth end of the smoking article,
the current actuation means can permit unrestricted or uninterrupted flow
of current through the resistive heating member to generate heat rapidly.
It can be useful to include current regulating components to regulate
current flow through the heater element to control heating rate and/or
heating duration.

[0052] The current regulating circuit particularly may be time based.
Specifically, such a circuit includes a means for permitting
uninterrupted current flow through the heating element for an initial
time period during draw, and a timer means for subsequently regulating
current flow until draw is completed. Further, regulation may comprise
simply allowing uninterrupted current flow until the desired temperature
is achieved then turning off the current flow completely. The heating
member may be reactivated by the consumer initiating another puff on the
article (or manually actuating the pushbutton, depending upon the
specific switch embodiment employed for activating the heater).
Alternatively, the subsequent regulation can involve the modulation of
current flow through the heating element to maintain the heating element
within a desired temperature range (including pulse width modulation). In
some embodiments, so as to release the desired dosing of the inhalable
substance, the heating member may be energized for a duration of about
0.2 second to about 5.0 seconds, about 0.3 second to about 4.5 seconds,
about 0.5 second to about 4.0 seconds, about 0.5 second to about 3.5
seconds, or about 0.6 second to about 3.0 seconds. Further description of
such time-based current regulating circuits and other control components
that can be useful in the present smoking article are provided in U.S.
Pat. Nos. 4,922,901, 4,947,874, and 4,947,875, all to Brooks et al., all
of which are incorporated herein by reference in their entireties.

[0053] The control components particularly can be configured to closely
control the amount of heat provided to the heater. In some embodiments,
the current regulating component can function to stop current flow to the
heater once a defined temperature has been achieved. Such defined
temperature can be in a range that is substantially high enough to
volatilize the aerosol precursor composition and any further inhalable
substances and provide an amount of aerosol in a desired concentration.
While the heat needed to volatilize the aerosol precursor composition can
vary, it can be particularly useful for the heater to heat to a
temperature of about 120° C. or greater, about 130° C. or
greater, about 140° C. or greater, or about 160° C. or
greater. In some embodiments, in order to volatilize a desired amount of
the aerosol precursor composition, the heating temperature may be about
180° C. or greater, about 200° C. or greater, about
300° C. or greater, or about 350° C. or greater. In further
embodiments, the defined temperature for aerosol formation can be about
120° C. to about 350° C., about 140° C. to about
300° C., or about 150° C. to about 250° C. The
temperature and time of heating can be controlled by one or more
components contained in the control housing. The current regulating
component likewise can cycle the current to the heater off and on once a
defined temperature has been achieved so as to maintain the defined
temperature for a defined period of time.

[0054] Still further, the current regulating component can cycle the
current to the heater off and on to maintain a first temperature that is
below an aerosol forming temperature and then allow an increased current
flow in response to a current actuation control component so as to
achieve a second temperature that is greater than the first temperature
and that is an aerosol forming temperature. Such controlling can improve
the response time of the article for aerosol formation such that aerosol
formation begins almost instantaneously upon initiation of a puff by a
consumer. In some embodiments, the first temperature (which can be
characterized as a standby temperature) can be only slightly less than
the aerosol forming temperature defined above. Specifically, the standby
temperature can be about 50° C. to about 150° C., about
70° C. to about 140° C., about 80° C. to about
120° C., or about 90° C. to about 110° C.

[0055] The resistive heating element can be formed of a material that
provides resistive heating when an electrical current is applied thereto.
Preferably, the resistive heating element exhibits an electrical
resistance making the resistive heating element useful for providing a
sufficient quantity of heat when electrical current flows therethrough.
In some embodiments, a flow rate heating algorithm can be applied whereby
heat output from the heating element is proportional to the flow rate of
air through the device.

[0056] Electrically conductive materials useful as resistive heating
elements can be those having low mass, low density, and moderate
resistivity and that are thermally stable at the temperatures experienced
during use. Useful heating elements heat up and cool down rapidly, and
thus provide for the efficient use of energy. Rapid heating of the
element can be beneficial to provide almost immediate volatilization of
an aerosol precursor material in proximity thereto. Rapid cooling
prevents substantial volatilization (and hence waste) of the aerosol
precursor material during periods when aerosol formation is not desired.
Such heating elements also permit relatively precise control of the
temperature range experienced by the aerosol precursor material,
especially when time based current control is employed. Useful
electrically conductive materials preferably are chemically non-reactive
with the materials being heated (e.g., aerosol precursor materials and
other inhalable substance materials) so as not to adversely affect the
flavor or content of the aerosol or vapor that is produced. Exemplary,
non-limiting, materials that can be used as the electrically conductive
material include carbon, graphite, carbon/graphite composites, metals,
metallic and non-metallic carbides, nitrides, silicides, inter-metallic
compounds, cermets, metal alloys, metal oxides, and metal foils. In
particular, refractory materials may be useful. Various, different
materials can be mixed to achieve the desired properties of resistivity,
mass, and thermal conductivity. In specific embodiments, metals that can
be utilized include, for example, nickel, chromium, alloys of nickel and
chromium (e.g., nichrome), and steel. Materials that can be useful for
providing resistive heating are described in U.S. Pat. No. 5,060,671 to
Counts et al.; U.S. Pat. No. 5,093,894 to Deevi et al.; 5,224,498 to
Deevi et al.; 5,228,460 to Sprinkel Jr., et al.; 5,322,075 to Deevi et
al.; U.S. Pat. No. 5,353,813 to Deevi et al.; U.S. Pat. No. 5,468,936 to
Deevi et al.; U.S. Pat. No. 5,498,850 to Das; U.S. Pat. No. 5,659,656 to
Das; U.S. Pat. No. 5,498,855 to Deevi et al.; U.S. Pat. No. 5,530,225 to
Hajaligol; U.S. Pat. No. 5,665,262 to Hajaligol; U.S. Pat. No. 5,573,692
to Das et al.; and U.S. Pat. No. 5,591,368 to Fleischhauer et al., the
disclosures of which are incorporated herein by reference in their
entireties.

[0057] The resistive heating element can be provided in a variety forms,
such as in the form of a foil, a foam, discs, spirals, fibers, wires,
films, yarns, strips, ribbons, or cylinders, as well as irregular shapes
of varying dimensions. In some embodiments, a resistive heating element
according to the present disclosure can be a conductive substrate, such
as described in co-pending U.S. patent application Ser. No. 13/432,406,
filed Mar. 28, 2012, the disclosure of which is incorporated herein by
reference in its entirety. The resistive heating element also may be
present as part of a microheater component, such as described in
co-pending U.S. patent application Ser. No. 13/602,871, filed Sep. 4,
2012, the disclosure of which is incorporated herein by reference in its
entirety.

[0058] The resistive heating element preferably is in electrical
connection with the power source of the smoking article such that
electrical energy can be provided to the resistive heating element to
produce heat and subsequently aerosolize the aerosol precursor
composition and its various components. Such electrical connection can be
permanent (e.g., hard wired) or can be removable (e.g., wherein the
resistive heating element is provided in a cartridge that can be attached
to and detached from a control body that includes the power source).

[0059] Beneficially, the resistive heating element can be provided in a
form that enables the heating element to be positioned in intimate
contact with or in close proximity to the aerosol precursor material. In
other embodiments, the resistive heating element can be provided in a
form such that the aerosol precursor material can be delivered to the
resistive heating element for aerosolization. For example, the aerosol
precursor composition (or components thereof) can be provided in liquid
form so as to allow the composition to flow from one or more reservoirs
to the resistive heating element, such as via capillary action through a
wick or other porous material. As such, the aerosol precursor composition
may be provided in liquid form in one or more reservoirs positioned
sufficiently away from the resistive heating element to prevent premature
aerosolization, but positioned sufficiently close to the resistive
heating element to facilitate transport of the aerosol precursor
composition, in the desired amount, to the resistive heating element for
aerosolization.

[0060] The amount of aerosol released by the inventive article can vary.
Preferably, the article is configured with a sufficient amount of the
aerosol precursor composition, with a sufficient amount of any further
inhalable substance, and to function at a sufficient temperature for a
sufficient time to release a desired content of aerosolized materials
over a course of use. The content may be provided in a single inhalation
from the article or may be divided so as to be provided through a number
of puffs from the article over a relatively short length of time (e.g.,
less than 30 minutes, less than 20 minutes, less than 15 minutes, less
than 10 minutes, or less than 5 minutes). For example, the article may
provide nicotine in an amount of about 0.01 mg to about 0.5 mg, about
0.05 mg to about 0.3 mg, or about 0.1 mg to about 0.2 mg per puff on the
article. For purposes of calculations, an average puff time of about 2
seconds can deliver a puff volume of about 5 ml to about 100 ml, about 15
ml to about 70 ml, about 20 ml to about 60 ml, or about 25 ml to about 50
ml. A smoking article according to the invention can be configured to
provide any number of puffs calculable by the total amount of aerosol or
other inhalable substance to be delivered divided by the amount to be
delivered per puff The one or more reservoirs can be loaded with the
appropriate amount of aerosol precursor or other inhalable substance to
achieve the desired number of puffs and/or the desired total amount of
material to be delivered.

[0061] In further embodiments, heating can be characterized in relation to
the amount of aerosol to be generated. Specifically, the article can be
configured to provide an amount of heat necessary to generate a defined
volume of aerosol (e.g., about 5 ml to about 100 ml, or any other volume
deemed useful in a smoking article, such as otherwise described herein).
In certain embodiments, the amount of heat generated can be measured in
relation to a two to four second puff providing about 35 ml of aerosol at
a heater temperature of about 290° C. In some embodiments, the
article preferably can provide about 1 to about 50 Joules of heat per
second (J/s), about 2 J/s to about 40 J/s, about 3 J/s to about 35 J/s,
or about 5 J/s to about 30 J/s.

[0062] The article can include one or more status indicators 19 positioned
on the shell 15. Such indicators can show the number of puffs taken or
remaining from the article, can be indicative of an active or inactive
status, can light up in response to a puff, or the like. Although six
indicators are illustrated, more or fewer indicators can be present, and
the indicators can take on different shapes and orientations and can even
be simply an opening in the shell (such as for release of sound when such
indicators are present). Such indicators may be lights (e.g., light
emitting diodes) that can provide indication of multiple aspects of use
of the inventive article. Further, LED indicators may be positioned at
the distal end of the smoking article to simulate color changes seen when
a conventional cigarette is lit and drawn on by a user. Other indices of
operation also are encompassed. For example, visual indicators also may
include changes in light color or intensity to show progression of the
smoking experience. Tactile indicators and audio indicators similarly are
encompassed by the invention. Moreover, combinations of such indicators
also may be used in a single article.

[0063] As seen in FIG. 1, a reservoir 205 illustrated as a container is
shown in proximity to the resistive heating element 50, and a transport
element 100 extends from the reservoir 205 and into sufficient proximity
with the resistive heating element such that the aerosol precursor
composition can be delivered to the resistive heating element for
aerosolization. In other embodiments, the reservoir can be a substrate
adapted to retain the aerosol precursor composition--e.g., can be a layer
of material that is at least partially saturated with the aerosol
precursor composition. Such layer can be absorbent, adsorbent, or
otherwise porous so as to provide the ability to retain the aerosol
precursor composition. As such, the aerosol precursor composition can be
characterized as being coated on, adsorbed by, or absorbed in a carrier
material (or substrate). The carrier material can be positioned within
the article to be in substantial contact with one or more transport
elements (e.g., wicks). More particularly, a reservoir can be a woven or
non-woven fabric or another mass of fibers or any further material
suitable for retaining the aerosol precursor composition (e.g., through
absorption, adsorption, capillary action, or the like) and allowing
wicking away of the precursor composition for transport to the resistive
heating element. Such reservoir layers can be formed of natural fibers,
synthetic fibers, or combinations thereof. Non-limiting examples of
useful materials include cotton, cellulose, polyesters, polyamides,
polylactic acids, combinations thereof, and the like. Similarly,
reservoirs can be formed of ceramics, other porous materials, sintered
materials, and the like. A smoking article according to the present
invention can include one reservoir or a plurality of reservoirs (e.g.,
two reservoirs, three reservoirs, four reservoirs, or even more). The
nature of reservoirs encompassed by the present disclosure is more
evident in relation to the discussion of the various figures of the
disclosure.

[0064] An article according to the present disclosure particularly can be
characterized in relation to the combination of the reservoir, transport
element, and heating element. The nature of these components as shown in
FIG. 1 illustrates only one embodiment, and further embodiments of
reservoirs, transport elements, and heaters (particularly in combination)
are described in greater particularity herein.

[0065] Formed aerosol is drawn by a user through the mouthend 11 of the
smoking article 10. The aerosol precursor composition that is aerosolized
by the heating of the resistive heating element can be continually
replenished (e.g., through wicking or other flow of the aerosol precursor
composition from the reservoir to the resistive heating element via the
transport element), or specific aliquots of the aerosol precursor
composition can be delivered to the resistive heating element on demand.
The cycle continues until substantially all of the aerosol precursor
composition has been aerosolized.

[0066] As seen in FIG. 1, the mouthend 11 of the article 10 can be
substantially an open cavity with the certain elements of the smoking
article disposed therein. Such open cavity provides a volume for release
of the aerosol formed at the resistive heating element. The article also
includes a mouth opening 18 in the mouthend 11 to allow for withdrawal of
the aerosol from the cavity. Although not expressly shown in the
illustration of FIG. 1, the article can include a filter material (such
as cellulose acetate or polypropylene) in the mouthend thereof to
increase the structural integrity thereof and/or to provide filtering
capacity, if desired, and/or to provide resistance to draw. To facilitate
air flow through the article, an air intake 17 can be provided and can
substantially comprise an aperture in the shell 15 that allows for air
flow into the interior of the article. A plurality of air intakes can be
provided, and the air intakes can be positioned at any location upstream
from the mouthend of the article such that air from the air intake can
mingle with and facilitate removal of the formed aerosol from the cavity
and through the opening in the mouthend of the article.

[0067] In some embodiments, an article as described herein can comprise
two units that are attachable and detachable from each other. For
example, FIG. 2 shows a smoking article 10 according to one embodiment
that is formed of a control body 80 and a cartridge 90. In specific
embodiments, the control body may be referred to as being reusable, and
the cartridge may be referred to as being disposable. In some
embodiments, the entire article may be characterized as being disposable
in that the control body may be configured for only a limited number of
uses (e.g., until a battery power component no longer provides sufficient
power to the article) with a limited number of cartridges and,
thereafter, the entire article 10, including the control body, may be
discarded. In other embodiments, the control body may have a replaceable
battery such that the control body can be reused through a number of
battery exchanges and with many cartridges. The article 10 can be
rechargeable and thus may be combined with any type of recharging
technology, including connection to a typical electrical outlet,
connection to a car charger (i.e., cigarette lighter receptacle), and
connection to a computer, such as through a USB cable. The article also
can be programmable as already discussed above.

[0068] The control body 80 and the cartridge 90 are specifically
configured so as to engage one another and form an interconnected,
functioning device. As illustrated in FIG. 2, the control body 80
includes a proximal attachment end 13 that includes a projection 82
having a reduced diameter in relation to the control body. The cartridge
includes a distal attachment end 14 that engages the proximal engagement
end of the control body 80 to provide the smoking article 10 in a
functioning, usable form. In FIG. 2, the control body projection 82
includes threads that allow the cartridge 90 to screw onto the control
body 80 via corresponding threads (not visible in FIG. 2) in the distal
attachment end of the cartridge. Thus, the distal attachment end of the
cartridge 90 can include an open cavity for receiving the control body
projection 82. Although a threaded engagement is illustrated in FIG. 2,
it is understood that further means of engagement are encompassed, such
as a press-fit engagement, a magnetic engagement, twist-lock engagement,
or the like.

[0069] In some embodiments, a cartridge according to the disclosure can
include one or more electronic control components and/or one or more
memory components. Various examples of electronic control components and
functions performed thereby that may be used in the devices of the
present disclosure are described in U.S. patent application Ser. No.
13/647,000, filed Oct. 8, 2012, which is incorporated herein by reference
in its entirety.

[0070] As noted above, a smoking article according to the present
disclosure can be particularly characterized in relation to the nature of
the transport element used to transport one or more components of an
aerosol precursor composition to a resistive heating element for
vaporization or aerosolization. More specifically, a smoking article
according to the present disclosure can include one or more wicks Ruined
of a plurality of individual filaments that are aligned in a defined
pattern. For example, the filaments may all be substantially parallel.
The individual filaments may be aligned so that substantially all of the
filaments have free ends pointed in the same direction or pointed toward
a specific point or area within the smoking article. More particularly,
the smoking article or a cartridge portion thereof can be characterized
as being formed of a hollow shell having the filaments of the wick
positioned therein. Specifically, the wick can be positioned within the
hollow shell so as to transport an aerosol precursor material inwardly
(relative an exterior wall of the hollow shell) toward a central axis
extending the length of the hollow shell. Alternatively, the wick can be
positioned within the hollow shell so as to transport an aerosol
precursor material outwardly (relative to the central axis extending the
length of the hollow shell) toward the exterior wall of the hollow shell.
Combinations of these configurations also are encompassed. The lengths of
the wick filaments can vary, and such variance can be random or can
define a specific pattern.

[0071] In specific embodiments, a wick for use according to the present
disclosure can be formed of a plurality of individual filaments aligned
in a brush-like configuration. Accordingly, the individual filaments of
the wick each can comprise a first end that is affixed to a holding
member and an opposing free end. Such holding member can be an
independent member of the present smoking article or a further element of
the smoking article can function as the holding member. For example, a
reservoir for use in retaining an aerosol precursor composition can also
function as the holding member for the individual filaments of the wick.
Alternatively, a holding member can be attached to, adjacent to, or
embedded in a reservoir to facilitate transport of the aerosol precursor
composition (or a component thereof) along the individual wick filaments.

[0072] In one aspect of the present disclosure, the individual filaments
of the wick can be circumferentially positioned around a segment of an
interior surface of the hollow shell. One embodiment of this aspect of
the invention is illustrated in FIG. 3 wherein a cartridge 90 of a
smoking article includes a wick 300 that is shown as a plurality of
individual filaments 301 lining the circumference of the interior of a
hollow shell 315. As further discussed herein, the filaments of the wick
can be formed of a variety of materials and have various shapes and
sizes.

[0073] As seen in FIG. 3, the cartridge 90 further includes a heating
element 350 that is in electrical contact with electrical leads 351,
which are in electrical connection to a battery so as to provide
electrical current to the heating element for resistive heating. Although
only a single heating element is illustrated, a plurality of heating
elements can be used. The heating element can be substantially a
resistance wire that can be intertwined with the filaments 301 of the
wick 300. More particularly, the heating element can be woven into the
wick in a unidirectional or multidirectional manner. In other words, the
heating element can be intertwined with the wick such that the heating
element forms substantially a unidirectional line around a circumference
of the interior of the smoking article; the heating element alternatively
can be multidirectional in that it can also extend axially in one or more
segments thereof and thus be substantially serpentine in shape around a
circumference of the interior of the smoking article.

[0074] A reservoir 305 is positioned between the wick 300 and the shell
315 and can retain an aerosol precursor composition or a component
thereof. The reservoir can be utilized as a holding member for the wick
in that the filaments of the wick are attached to or embedded in the
reservoir to form a fluid connection that enables transport of the
aerosol precursor composition out of the reservoir. The filaments can be
characterized as having a first end that is connected to the holding
member and a second end (i.e., an opposing end) that can be free.
Transport of the aerosol precursor composition, or a component thereof,
therefore can proceed from the first end of the filament toward the
second end of the filament. Heating of the filaments by the heating
element 350 thus forms a vapor or aerosol that is released into the open
central cavity 303 for passage axially along the cartridge 90 to a
mouthpiece (not shown) or simply an opening in the shell at an end
thereof (e.g., element 18 in FIG. 1).

[0075] In the cross-section of FIG. 3, the wick 300 has the appearance of
a single row of the filaments 301 encircling the interior of the shell
315, but the smoking article of the disclosure is not so limited. Rather,
the wick 300 can have width that can vary from about the width of a
single filament to about a width corresponding to about the entire length
of a cartridge 90 (see FIG. 2). In certain embodiments, the width of the
wick can vary from about 0.5 mm to about 40 mm, about 0.6 mm to about 30
mm, about 0.7 mm to about 20 mm, about 0.8 mm to about 10 mm, about 0.9
mm to about 8 mm, or about 1 mm to about 5 mm. The wick also can be
characterized in relation to filament density. Specifically, the wick can
have a filament density of about 0.25 filaments per mm2 to about 20
filaments per mm2, about 0.5 filaments per mm2 to about 10
filaments per mm2, or about 1 filament per mm2 to about 5
filaments per mm2. The shape and length of the heating element thus
can vary based upon one or more of the number of heating elements
present, the width of the wick to be heated by the heating element, and
the filament density of the wick.

[0076] In some embodiments, a single wick 300 can be present and can have
a width as described above. In other embodiments, a plurality of wicks
can be included within the shell 315. For example, a plurality of wicks
can be used such that the filaments 301 can be circumferentially
positioned around a plurality of segments of the interior surface of the
shell. One such embodiment is illustrated in FIG. 4.

[0077] In the embodiment of FIG. 4, a portion of the shell 315 (partially
cut away) of a cartridge 90 includes a first wick 300 formed of a
plurality of filaments 301 in a fluid connection with a first reservoir
305 that also functions as a holding member for the filaments. A first
heating element 350 in the form of a metal wire is coiled around the
interior of the reservoir so as to be intertwined with the wick. Two
coils are shown, but more coils can be present, and a plurality of metal
wires can be utilized with the same wick. The heating element is
connected to electrical leads 351 that are connected to the appropriate
wiring (not shown) to form an electrical connection with a battery, such
as can be housed in a control element that is adapted for connection to
the cartridge. In the same cartridge is a second wick 400 formed of a
plurality of filaments 401 in a fluid connection with a second reservoir
405 that also functions as a holding member for the filaments. A second
heating element 450 in the form of a metal wire is intertwined with the
wick in a serpentine fashion to provide for increased heating density. A
single heating element is shown, but a plurality of heating wires can be
present for use with the same wick. The second heating element is
connected to electrical leads 451 that are connected to the appropriate
wiring (not shown) to form an electrical connection with a battery.

[0078] As seen in FIG. 3 and FIG. 4, the individual filaments of the wick
can be irregularly shaped and can vary in length. In other embodiments,
the filaments can be substantially straight and, independently, can be
all substantially the same length. When the wick is circumferentially
positioned, it can be preferable for the wick length to be of a length
that provides for a sufficient volume of the aerosol precursor
composition to transport thereby for aerosolization to achieve a desired
aerosol volume. Further, the length can be sufficiently short to provide
an internal open space within the shell (e.g., within a cartridge) for
aerosol formation. For example, the filaments of the wick can have a
length of about 0.5 mm to about 5 mm, about 1 mm to about 4.5 mm, or
about 1.5 mm to about 4 mm.

[0079] In other embodiments, the filaments of the wick used according to
the present disclosure can be axially aligned along a length of the
hollow shell. In other words, the wick can extend from or near the
mouthend to or near the distal attachment end of a cartridge (elements 11
and 14, respectively, of FIG. 2). It is not required, however, for the
wick to extend the entire length of the shell of the component in which
it is included and can rather extend along only a portion of the length
of the shell. For example, an axially aligned wick can have a length of
about 2 mm to about 50 mm, about 5 mm to about 45 mm, or about 10 mm to
about 40 mm.

[0080] In certain embodiments, the axial alignment of the wick can be
substantially linear in nature. An exemplary embodiment is shown in FIG.
5 wherein a portion of a cartridge 90 with a partially transparent outer
wall 516 is shown with two wicks 500 extending along a partial length of
the shell 515. The wicks are in fluid connection with reservoirs 505 that
include an aerosol precursor composition or a component thereof, and the
reservoirs can function as the holding member for the filaments 501 of
the wicks. As illustrated, the wicks are substantially perpendicular to
the axis of the reservoir. The present disclosure is not limited to such
embodiments, however, and the individual elements of the wick can be
present at a variety of angles relative to the reservoir and/or relevant
to any further holding member that is present. In specific embodiments,
the individual filaments can be at an angle relative to the reservoir
and/or holding member of about 10° to about 170°, about
15° to about 165°, about 30° to about 150°,
or about 45° to about 135°. Heating elements 550 are shown
intermingled with the filaments of the wicks. As can be seen, the heating
elements (e.g., resistance heating wires) likewise can be axially aligned
along a length of the shell. In the illustrated embodiment, the filaments
are substantially uniform in length, but uneven filaments or filaments of
irregular length can be used. From the illustrated view, the wick appears
to include only a single row of filaments, and such embodiments are
encompassed. The present disclosure also encompasses, however, axially
aligned wicks that include a plurality of rows of filaments or a
plurality of randomly positioned filaments.

[0081] As seen in FIG. 6, the axially aligned wicks 600 can be positioned
in multiple locations around the interior of the shell 615. Also, as is
more evident in the exemplified embodiment, the wicks can be formed of a
plurality of rows of individual filaments or a plurality of randomly
positioned filaments. Although only a single heating element 650 is shown
in each wick, a plurality of heating elements of the same or different
configurations can be utilized with each wick. This embodiment also
illustrates a holding member 675 that is separate from the reservoir 605.
The separate holding member can be formed of any material suitable for
securing the individual filaments in position so long as it does not
significantly reduce the fluid transport of the aerosol precursor
composition from the reservoir to the wick filaments. For example, the
holding member can be a woven fabric or a porous, solid substrate, such
as a ceramic, or can be formed of another solid material, such as a
plastic or metal. Although the reservoir is shown as completely
encompassing the inner circumference of the shell, the reservoir can be
present only in discrete areas substantially corresponding to the
locations of the wicks.

[0082] The use of a plurality of individual wicks can be beneficial for
separately heating one or more components of the aerosol precursor
composition. For example, a flavor and/or a medicament can be retained in
a first reservoir associated with a first wick, and a polyol can be
retained in a second reservoir associated with a second wick. During use,
the control components of the smoking article can be adapted to provide
for different heating profiles for the heating members associated with
the first and second wicks. For example, the first heating element can be
heated to a greater or lesser temperature than the second heating element
and/or can be activated for a greater or lesser total heating time than
the second heating element. Similarly, the first or second heating
element can be activated separately from the other and can be controlled
in a different manner than the other. For example, the first heating
element can be associated with a wick/reservoir combination that only
provides a flavor component, and the second heating element can be
associated with a wick/reservoir combination that provides further
aerosol precursors. The second heating element thus can be activated
responsive to the puff sensor, as described above, and the first heating
element can be activated by manual activation to release the flavor only
when desired by the user. Moreover, one wick can include a greater number
of heating elements than one or more further wicks so that greater
overall heating is provided in the wick with the greater number of
heating elements. Other combinations of uses of the different
wick/reservoir/heater combinations also are encompassed by the present
disclosure.

[0083] In still other embodiments, the axial alignment of the wick does
not necessarily require that wick to be linear in nature. One exemplary,
non-linear arrangement is shown in FIG. 7, wherein the axial alignment is
substantially helical. In FIG. 7, a cartridge 90 is shown with a
partially transparent outer wall 716. In such embodiments, the reservoir
705 can be substantially in a ribbon arrangement wrapped around the
interior of the shell 715 to take on a helical shape. The individual
filaments 701 of the wick 700 can be arranged on a single side of the
reservoir, and a further holding member may be included with the
wick/reservoir arrangement if desired. As can be seen in a comparison of
FIG. 7 with FIG. 4, the filament density can be varied as necessary to
provide desired wicking properties, which can vary based upon the
composition being transported and the desired volume (or rate of
formation) of vapor to be formed.

[0084] Generally, the filaments of the wick can be positioned such that
the free ends of the filaments are directed inward toward a central axis
of the shell. In some embodiments, the diameter of the wick helix can be
reduced so as to allow for the presence of filaments on opposing sides of
the reservoir/holding member--i.e., such that filaments are directed
outward toward the outer wall of the shell as well as being directed
inward, as described above. In still other embodiments, the
reservoir/holding member can be substantially circular in cross-section
(as opposed to substantially flattened, as shown in FIG. 7), and the
filaments can be positioned around the circular reservoir/holding member
along any arc sector up to and including 360° (i.e., around a part
or the entire circumference of the circular reservoir/holding member).
Other geometrical cross-sections (e.g., square or triangular) are also
encompassed for the reservoir/holding member, and the wick filaments can
be positioned accordingly around a part or the entirety of the
reservoir/holding member having a further cross-sectional shape in line
with the discussion already provided above. As before, the axially
aligned, helical wick can be present along any portion of the length of
the shell (e.g., the length of a cartridge).

[0085] While the foregoing has described non-limiting examples of wick
arrangements that provide primarily (or in part) inward wicking or inward
transport of aerosol precursor components relative to the hollow shell,
the present disclosure also encompasses outward wicking or outward
transport of aerosol precursor components relative to the hollow shell.
For example, in some embodiments, the individual filaments of the wick
can be positioned about a central axis of the hollow shell such that the
free ends of the filaments are directed outward toward an outer wall of
the hollow shell. Some embodiments of such outward wicking are captured
above in relation to various possible configurations of the wick
filaments about a reservoir/holding member having different geometrical
cross-sections. In other embodiments, however, an article according to
the present disclosure can include a central member extending along the
central axis of the hollow shell through at least a portion of the length
of the hollow shell. One such embodiment is illustrated in FIG. 8,
wherein a wick 800 is formed of a plurality of filaments 801 that are
circumferentially positioned around the central member 805 along at least
a partial length (or segment) of the central member. In this embodiment,
the central member is also the reservoir retaining the liquid aerosol
precursor composition. In other embodiments, the central member can be
separate and distinct from the reservoir. For example, the central member
can be a separate holding member for the wick filaments, or the central
member can be a structural component of the cartridge. In such cases, a
separate reservoir can be provided in fluid communication with the wick.

[0086] In FIG. 8, the filaments encompass a 360° arc sector of the
central member reservoir 805. In other embodiments, the filaments can be
positioned around the central member reservoir along any arc sector up to
and including 360° (i.e., around a part or the entire
circumference of the central member reservoir). If desired, the reservoir
can be positioned off-center such that an exact center alignment relative
to the outer wall of the hollow shell 815 is not required. As needed, one
or more positional supports 880 can be present to retain the central
member at its location within the hollow shell. The positional supports
can take on any arrangement that does not substantially impede flow of
air and aerosol or vapor through the hollow shell. As before, a heating
member 850 is intertwined with the filaments 801 of the wick 800 and is
in electrical connection with the battery or other element that provides
electrical energy to the article. Further, a plurality of heating
elements can be used.

[0087] If desired, a plurality of outwardly wicking wicks can be present
on separate segments of the central member and can be separated by spaces
where no wicking element is present. Thus, a series of two or more wicks
of varying width can be present along the length of a central member
present within the hollow shell. In the words, the filaments can be
circumferentially positioned around a plurality of segments of the
central member, and such segments can be separated by a defined, open
space. This arrangement can be similar to the discrete, separate wicks
illustrated in FIG. 4 in the inward wicking arrangement.

[0088] In further embodiments, the wick filaments can be axially aligned
along a length of the central member. One such embodiment is illustrated
in FIG. 9, wherein a plurality of wicks (900a, 900b, 900c, 900d) each
formed of a plurality of filaments 901 are positioned around discrete arc
sectors of the central member (or central reservoir) 905. As illustrated
in FIG. 9, the central member 905 can be formed of a plurality of
discrete reservoirs (906, 907, 908, 909) corresponding to the discrete
wicks, and the discrete reservoirs can retain different materials for
aerosolization. The reservoir can be divided into more or fewer sections
as desired, and two or more of the reservoirs can include compositions of
overlapping components. Alternately, the central reservoir can be a
singular member, and one wick or a plurality of wicks can extend radially
therefrom. Each wick can have an associated heating member (950a, 950b,
950c, 950d). A plurality of heating members can be used with one or more
of the wicks. As before, the presence of a plurality of wicks and a
plurality of heaters can allow for separate heating of the separate wicks
to provide of a variety of heating profiles wherein the aerosol precursor
composition (or components thereof) can be heated differently to achieve
a number of programmable aerosol compositions.

[0089] Yet another embodiment of the disclosure is shown in FIG. 10,
wherein the axial alignment of the wick 1000 with its individual
filaments 1001 is shown to be substantially a straight line. Moreover,
the filaments can be aligned in a plurality of rows along the length of
the central member (or central reservoir) 10005. The wick (and the
central member) can extend along all or part of the length of the hollow
shell 1015 of the cartridge 90 or other element of an article according
to the disclosure. In the same manner as seen in FIG. 9, the plurality of
rows of the filaments can be present at one or more arc sectors of the
central member. In other embodiments, the central member can take on a
different geometrical cross-section, such as square or triangular), and a
plurality of wicks can be present on one or more sides of the central
member. Moreover, as illustrated in relation to FIG. 7, the outwardly
wicking, axially aligned wick can have an axial alignment that is
substantially helical around the central member.

[0090] The filaments used in a wick according to the present disclosure
can be formed of any material that is thermally stable and that provides
sufficient wicking action to transport one or more components of the
aerosol precursor composition along the length of the filament.
Non-limiting examples include natural and synthetic fibers, such as
cotton, cellulose, polyesters, polyamides, polylactic acids, glass
fibers, combinations thereof, and the like. Other exemplary materials
that can be used in wicks include metals, ceramics, and carbonized
filaments (e.g., a material formed of a carbonaceous material that has
undergone calcining to drive off non-carbon components of the material).

[0091] The filaments (or the wick generally) can be coated with materials
that alter the capillary action of the filaments--i.e., to increase (or
decrease, if desired) the wicking action of the filament. Also, fiber
material selection can be utilized to increase or decrease wicking action
and thus control the wicking rate of a specific component of the aerosol
precursor composition. Wicking also can be customized through choice of
the dimensions of the fibers used in the wicks and the overall dimensions
of the wick, including wick length and wick diameter.

[0092] The filaments used in forming wicks can have specific
cross-sectional shape and/or can be grooved so as to alter the capillary
action of the fibers. Typical filaments have a substantially round
cross-section, and altering fiber cross-section shape can increase the
surface area per denier of the fiber and thus improve wicking along the
filament. For example, a filament can be formed with longitudinal grooves
that are intended to facilitate wicking, such as a 4DG fiber (available
from Fiber Innovation Technology) and winged fibers (available from
Alasso Industries). Filaments formed with an "X" or "Y" shaped
cross-section similarly can provide desirable wicking properties.

[0093] Filaments useful according to the present disclosure also can
include filaments having physical alterations thereof For example,
filaments can be scored or partially cut along the length thereof so as
to increase the overall exposed surface area of the filament. Such scores
or cuts can be made at any angle greater than 0° and less than
180° relative to the axis of the filament.

[0094] In other embodiments, at least a portion of a filament utilized in
a wick can be designed to promote radial wicking. Continuous filament
fibers, such as fiberglass, tend to promote wicking primarily along the
axis of the filament--i.e., axial wicking. Through appropriate design,
the filament also can be caused to promote radial wicking--i.e., outward
from the axis of the filament. For example, radial wicking can be
facilitated through use of filaments having a fibrillated fiber surface.
Such design particularly can be useful in the area of the filaments that
are in proximity to or in contact with the heater as it can cause more of
the precursor composition to be available for aerosolization in the
specific area of the heater. A similar effect can be achieved such as
through the use of particles or beads that can be sintered or otherwise
interconnected to provide a continuous wick structure.

[0095] Filaments used in forming wicks can be provided singly or can be
bundled (including meshes and braids). In other words, a filament can be
a single fiber, or a filament can be formed of a group of combined fibers
that provide a larger mass. Porosity of the filaments used in the wick
also can be controlled to alter the capillary action and can include
controlling average pore size and total porosity, controlling filament
geometry, controlling overall wick shape, and controlling surface
characteristics. Separate filaments also can have different lengths.
Varying the nature of the filaments can be useful to customize vapor
formation. For example, filaments with greater wicking ability can be
used to transport a component of an aerosol precursor composition that is
desired to be vaporized in a high amount, and filaments with a reduced
wicking ability can be sued to transport a component of an aerosol
precursor composition that is desired to be vaporized in a lesser amount.

[0096] The type of material used to form the individual filaments of the
wicks also can be customized to transport specific types of compounds.
For example, one or more wicks can be formed of filaments utilizing
hydrophobic materials so as to preferentially wick hydrophobic liquids.
Further, one or more wicks can be formed of filaments utilizing
hydrophilic materials so as to preferentially wick hydrophilic liquids.
Moreover, one or more wicks can include filaments formed of materials
that are neither hydrophilic nor hydrophobic, such as natural materials,
so as to preferentially wick liquids that are neither significantly polar
nor significantly non-polar.

[0097] The aerosol precursor composition utilized in an article according
to the present disclosure can be formed of a variety of individual
components. Preferably, the aerosol precursor composition can include at
least one aerosol forming material, such as a polyol. The aerosol
precursor composition further can include a number of additional
components, including flavorings and medicaments.

[0098] In certain embodiments, a smoking article according to the present
disclosure can include tobacco, a tobacco component, or a tobacco-derived
material (i.e., a material that is found naturally in tobacco that may be
isolated directly from the tobacco or synthetically prepared). The
tobacco that is employed can include, or can be derived from, tobaccos
such as flue-cured tobacco, burley tobacco, Oriental tobacco, Maryland
tobacco, dark tobacco, dark-fired tobacco and Rustica tobacco, as well as
other rare or specialty tobaccos, or blends thereof Various
representative tobacco types, processed types of tobaccos, and types of
tobacco blends are set forth in U.S. Pat. No. 4,836,224 to Lawson et al.;
U.S. Pat. No. 4,924,888 to Perfetti et al.; U.S. Pat. No. 5,056,537 to
Brown et al.; U.S. Pat. No. 5,159,942 to Brinkley et al.; U.S. Pat. No.
5,220,930 to Gentry; U.S. Pat. No. 5,360,023 to Blakley et al.; U.S. Pat.
No. 6,701,936 to Shafer et al.; U.S. Pat. No. 6,730,832 to Dominguez et
al., U.S. Pat. No. 7,011,096 to Li et al.; U.S. Pat. No. 7,017,585 to Li
et al.; U.S. Pat. No. 7,025,066 to Lawson et al.; US Pat. App. Pub. No.
2004/0255965 to Perfetti et al.; PCT Pub. WO 02/37990 to Bereman; and
Bombick et al., Fund, Appl. Toxicol., 39, p. 11-17 (1997); the
disclosures of which are incorporated herein by reference in their
entireties.

[0099] The tobacco that is incorporated within the smoking article can be
employed in various forms; and combinations of various forms of tobacco
can be employed, or different forms of tobacco can be employed at
different locations within the smoking article. For example, the tobacco
can be employed in the form of a tobacco extract. See, for example, U.S.
Pat. No. 7,647,932 to Cantrell et al. and US Pat. Pub. No. 2007/0215167
to Crooks et al., the disclosures of which are incorporated herein by
reference in their entireties.

[0100] The smoking article can incorporate tobacco additives of the type
that are traditionally used for the manufacture of tobacco products.
Those additives can include the types of materials used to enhance the
flavor and aroma of tobaccos used for the production of cigars,
cigarettes, pipes, and the like. For example, those additives can include
various cigarette casing and/or top dressing components. See, for
example, U.S. Pat. No. 3,419,015 to Wochnowski; U.S. Pat. No. 4,054,145
to Berndt et al.; U.S. Pat. No. 4,887,619 to Burcham, Jr. et al.; U.S.
Pat. No. 5,022,416 to Watson; U.S. Pat. No. 5,103,842 to Strang et al.;
and U.S. Pat. No. 5,711,320 to Martin; the disclosures of which are
incorporated herein by reference in their entireties. Preferred casing
materials include water, sugars and syrups (e.g., sucrose, glucose and
high fructose corn syrup), humectants (e.g. glycerin or propylene
glycol), and flavoring agents (e.g., cocoa and licorice). Those added
components also include top dressing materials (e.g., flavoring
materials, such as menthol). See, for example, U.S. Pat. No. 4,449,541 to
Mays et al., the disclosure of which is incorporated herein by reference
in its entirety. Further materials that can be added include those
disclosed in U.S. Pat. No. 4,830,028 to Lawson et al. and US Pat. Pub.
No. 2008/0245377 to Marshall et al., the disclosures of which are
incorporated herein by reference in their entireties.

[0101] Various manners and methods for incorporating tobacco into smoking
articles, and particularly smoking articles that are designed so as to
not purposefully burn virtually all of the tobacco within those smoking
articles, are set forth in U.S. Pat. No. 4,947,874 to Brooks et al.; U.S.
Pat. No. 7,647,932 to Cantrell et al.; US Pat. App. Pub. No. 2005/0016549
to Banerjee et al.; and US Pat. App. Pub. No. 2007/0215167 to Crooks et
al.; the disclosures of which are incorporated herein by reference in
their entireties.

[0102] Further tobacco materials, such as a tobacco aroma oil, a tobacco
essence, a spray dried tobacco extract, a freeze dried tobacco extract,
tobacco dust, or the like may be included in the vapor precursor or
aerosol precursor composition. As used herein, the term "tobacco extract"
means components separated from, removed from, or derived from, tobacco
using tobacco extraction processing conditions and techniques. Purified
extracts of tobacco or other botanicals specifically can be used.
Typically, tobacco extracts are obtained using solvents, such as solvents
having an aqueous nature (e.g., water) or organic solvents (e.g.,
alcohols, such as ethanol or alkanes, such as hexane). As such, extracted
tobacco components are removed from tobacco and separated from the
unextracted tobacco components; and for extracted tobacco components that
are present within a solvent, (i) the solvent can be removed from the
extracted tobacco components, or (ii) the mixture of extracted tobacco
components and solvent can be used as such. Exemplary types of tobacco
extracts, tobacco essences, solvents, tobacco extraction processing
conditions and techniques, and tobacco extract collection and isolation
procedures, are set forth in Australia Pat. No. 276,250 to Schachner;
U.S. Pat. No. 2,805,669 to Meriro; U.S. Pat. No. 3,316,919 to Green et
al.; U.S. Pat. No. 3,398,754 to Tughan; U.S. Pat. No. 3,424,171 to
Rooker; U.S. Pat. No. 3,476,118 to Luttich; U.S. Pat. No. 4,150,677 to
Osborne; U.S. Pat. No. 4,131,117 to Kite; U.S. Pat. No. 4,506,682 to
Muller; U.S. Pat. No. 4,986,286 to Roberts et al.; U.S. Pat. No.
5,005,593 to Fagg; U.S. Pat. No. 5,065,775 to Fagg; U.S. Pat. No.
5,060,669 to White et al.; U.S. Pat. No. 5,074,319 to White et al.; U.S.
Pat. No. 5,099,862 to White et al.; U.S. Pat. No. 5,121,757 to White et
al.; U.S. Pat. No. 5,131,415 to Munoz et al.; U.S. Pat. No. 5,230,354 to
Smith et al.; U.S. Pat. No. 5,235,992 to Sensabaugh; U.S. Pat. No.
5,243,999 to Smith; U.S. Pat. No. 5,301,694 to Raymond; U.S. Pat. No.
5,318,050 to Gonzalez-Pana et al.; U.S. Pat. No. 5,435,325 to Clapp et
al.; and U.S. Pat. No. 5,445,169 to Brinkley et al.; the disclosures of
which are incorporated herein by reference in their entireties.

[0103] The aerosol precursor or vapor precursor composition preferentially
can include a polyhydric alcohol (e.g., glycerin, propylene glycol, or a
mixture thereof). Representative types of further aerosol precursor
compositions are set forth in U.S. Pat. No. 4,793,365 to Sensabaugh, Jr.
et al.; U.S. Pat. No. 5,101,839 to Jakob et al.; PCT WO 98/57556 to Biggs
et al.; and Chemical and Biological Studies on New Cigarette Prototypes
that Heat Instead of Burn Tobacco, R. J. Reynolds Tobacco Company
Monograph (1988); the disclosures of which are incorporated herein by
reference. In some embodiments, an aerosol precursor composition can
produce a visible aerosol upon the application of sufficient heat thereto
(and cooling with air, if necessary), and the aerosol precursor
composition can produce an aerosol that can be considered to be
"smoke-like." In other embodiments, the aerosol precursor composition can
produce an aerosol that can be substantially non-visible but can be
recognized as present by other characteristics, such as flavor or
texture. Thus, the nature of the produced aerosol can vary depending upon
the specific components of the aerosol precursor composition. The aerosol
precursor composition can be chemically simple relative to the chemical
nature of the smoke produced by burning tobacco.

[0104] Aerosol precursor compositions can include further liquid
materials, such as water. For example, aerosol precursor compositions can
incorporate mixtures of glycerin and water, or mixtures of propylene
glycol and water, or mixtures of propylene glycol and glycerin, or
mixtures of propylene glycol, glycerin, and water. Exemplary aerosol
precursor compositions also include those types of materials incorporated
within devices available through Atlanta Imports Inc., Acworth, Ga.,
USA., as an electronic cigar having the brand name E-CIG, which can be
employed using associated Smoking Cartridges Type C1a, C2a, C3a, C4a,
C1b, C2b, C3b and C4b; and as Ruyan Atomizing Electronic Pipe and Ruyan
Atomizing Electronic Cigarette from Ruyan SBT Technology and Development
Co., Ltd., Beijing, China.

[0105] The aerosol precursor composition used in the disclosed smoking
article further can comprise one or more flavors, medicaments, or other
inhalable materials. For example, liquid nicotine can be used. Such
further materials can comprise one or more components of the aerosol
precursor or vapor precursor composition. Thus, the aerosol precursor or
vapor precursor composition can be described as comprising an inhalable
substance. Such inhalable substance can include flavors, medicaments, and
other materials as discussed herein. Particularly, an inhalable substance
delivered using a smoking article according to the present invention can
comprise a tobacco component or a tobacco-derived material. Alternately,
the flavor, medicament, or other inhalable material can be provided
separate from other aerosol precursor components--e.g., in a reservoir.
As such, defined aliquots of the flavor, medicament, or other inhalable
material may be separately or simultaneously delivered to the resistive
heating element to release the flavor, medicament, or other inhalable
material into an air stream to be inhaled by a user along with the
further components of the aerosol precursor or vapor precursor
composition.

[0106] A wide variety of types of flavoring agents, or materials that
alter the sensory or organoleptic character or nature of the mainstream
aerosol of the smoking article, can be employed. Such flavoring agents
can be provided from sources other than tobacco, can be natural or
artificial in nature, and can be employed as concentrates or flavor
packages. Of particular interest are flavoring agents that are applied
to, or incorporated within, those regions of the smoking article where
aerosol is generated. Again, such agents can be supplied directly to the
resistive heating element or may be provided on a substrate as already
noted above. Exemplary flavoring agents include vanillin, ethyl vanillin,
cream, tea, coffee, fruit (e.g., apple, cherry, strawberry, peach and
citrus flavors, including lime and lemon), maple, menthol, mint,
peppermint, spearmint, wintergreen, nutmeg, clove, lavender, cardamom,
ginger, honey, anise, sage, cinnamon, sandalwood, jasmine, cascarilla,
cocoa, licorice, and flavorings and flavor packages of the type and
character traditionally used for the flavoring of cigarette, cigar, and
pipe tobaccos. Syrups, such as high fructose corn syrup, also can be
employed. Flavoring agents also can include acidic or basic
characteristics (e.g., organic acids, such as levulinic acid, succinic
acid, lactic acid, and pyruvic acid). The flavoring agents can be
combined with the aerosol-generating material if desired. Exemplary
plant-derived compositions that may be used are disclosed in U.S.
application Ser. No. 12/971,746 to Dube et al. and U.S. application Ser.
No. 13/015,744 to Dube et al., the disclosures of which are incorporated
herein by reference in their entireties.

[0107] Organic acids particularly may be incorporated into the aerosol
precursor to provide desirable alterations to the flavor, sensation, or
organoleptic properties of medicaments, such as nicotine, that may be
combined with the aerosol precursor. For example, organic acids, such as
levulinic acid, succinic acid, lactic acid, and pyruvic acid, may be
included in the aerosol precursor with nicotine in amounts up to being
equimolar (based on total organic acid content) with the nicotine. Any
combination of organic acids can be used. For example, the aerosol
precursor can include about 0.1 to about 0.5 moles of levulinic acid per
one mole of nicotine, about 0.1 to about 0.5 moles of pyruvic acid per
one mole of nicotine, about 0.1 to about 0.5 moles of lactic acid per one
mole of nicotine, or combinations thereof, up to a concentration wherein
the total amount of organic acid present is equimolar to the total amount
of nicotine present in the aerosol precursor.

[0108] In embodiments of the aerosol precursor material that contain a
tobacco extract, including pharmaceutical grade nicotine derived from
tobacco, it is advantageous for the tobacco extract to be characterized
as substantially free of compounds collectively known as Hoffmann
analytes, including, for example, tobacco-specific nitrosamines (TSNAs),
including N'-nitrosonomicotine (NNN),
(4-methylnitrosamino)-1-(3-pyridyl)-1-butanone (NNK), N'-nitrosoanatabine
(NAT), and N'-nitrosoanabasine (NAB); polyaromatic hydrocarbons (PAHs),
including benz[a]anthracene, benzo[a]pyrene, benzo[b]fluoranthene,
benzo[k]fluoranthene, chrysene, dibenz[a,h]anthracene, and
indeno[1,2,3-cd]pyrene, and the like. In certain embodiments, the aerosol
precursor material can be characterized as completely free of any
Hoffmann analytes, including TSNAs and PAHs. Embodiments of the aerosol
precursor material may have TSNA levels (or other Hoffmann analyte
levels) in the range of less than about 5 ppm, less than about 3 ppm,
less than about 1 ppm, or less than about 0.1 ppm, or even below any
detectable limit. Certain extraction processes or treatment processes can
be used to achieve reductions in Hoffmann analyte concentration. For
example, a tobacco extract can be brought into contact with an imprinted
polymer or non-imprinted polymer such as described, for example, in US
Pat. Pub. Nos. 2007/0186940 to Bhattacharyya et al; 2011/0041859 to Rees
et al.; and 2011/0159160 to Jonsson et al; and U.S. patent application
Ser. No. 13/111,330 to Byrd et al., filed May 19, 2011, all of which are
incorporated herein by reference. Further, the tobacco extract could be
treated with ion exchange materials having amine functionality, which can
remove certain aldehydes and other compounds. See, for example, U.S. Pat.
Nos. 4,033,361 to Horsewell et al. and 6,779,529 to Figlar et al., which
are incorporated herein by reference in their entireties.

[0109] The aerosol precursor composition may take on a variety of
conformations based upon the various amounts of materials utilized
therein. For example, a useful aerosol precursor composition may comprise
up to about 98% by weight up to about 95% by weight, or up to about 90%
by weight of a polyol. This total amount can be split in any combination
between two or more different polyols. For example, one polyol can
comprise about 50% to about 90%, about 60% to about 90%, or about 75% to
about 90% by weight of the aerosol precursor, and a second polyol can
comprise about 2% to about 45%, about 2% to about 25%, or about 2% to
about 10% by weight of the aerosol precursor. A useful aerosol precursor
also can comprise up to about 25% by weight, about 20% by weight or about
15% by weight water--particularly about 2% to about 25%, about 5% to
about 20%, or about 7% to about 15% by weight water. Flavors and the like
(which can include medicaments, such as nicotine) can comprise up to
about 10%, up to about 8%, or up to about 5% by weight of the aerosol
precursor.

[0110] As a non-limiting example, an aerosol precursor according to the
invention can comprise glycerol, propylene glycol, water, nicotine, and
one or more flavors. Specifically, the glycerol can be present in an
amount of about 70% to about 90% by weight, about 70% to about 85% by
weight, or about 75% to about 85% by weight, the propylene glycol can be
present in an amount of about 1% to about 10% by weight, about 1% to
about 8% by weight, or about 2% to about 6% by weight, the water can be
present in an amount of about 10% to about 20% by weight, about 10% to
about 18% by weight, or about 12% to about 16% by weight, the nicotine
can be present in an amount of about 0.1% to about 5% by weight, about
0.5% to about 4% by weight, or about 1% to about 3% by weight, and the
flavors can be present in an amount of up to about 5% by weight, up to
about 3% by weight, or up to about 1% by weight, all amounts being based
on the total weight of the aerosol precursor. One specific, non-limiting
example of an aerosol precursor comprises about 75% to about 80% by
weight glycerol, about 13% to about 15% by weight water, about 4% to
about 6% by weight propylene glycol, about 2% to about 3% by weight
nicotine, and about 0.1% to about 0.5% by weight flavors. The nicotine,
for example, can be a from a tobacco extract.

[0111] The amount of aerosol precursor composition that is used within the
smoking article is such that the article exhibits acceptable sensory and
organoleptic properties, and desirable performance characteristics. For
example, it is highly preferred that sufficient aerosol precursor
composition components, such as glycerin and/or propylene glycol, be
employed in order to provide for the generation of a visible mainstream
aerosol that in many regards resembles the appearance of tobacco smoke.
Typically, the amount of aerosol-generating material incorporated into
the smoking article is in the range of about 1.5 g or less, about 1 g or
less, or about 0.5 g or less. The amount of aerosol precursor composition
can be dependent upon factors such as the number of puffs desired per
cartridge used with the smoking article. It is desirable for the aerosol
precursor composition not to introduce significant degrees of
unacceptable off-taste, filmy mouth-feel, or an overall sensory
experience that is significantly different from that of a traditional
type of cigarette that generates mainstream smoke by burning tobacco cut
filler. The selection of the particular aerosol-generating material and
reservoir material, the amounts of those components used, and the types
of tobacco material used, can be altered in order to control the overall
chemical composition of the mainstream aerosol produced by the smoking
article.

[0112] Typically, the aerosol precursor composition utilized in the
smoking article will be formed of a first component and at least a
second, separate component. Thus, the aerosol precursor composition can
be formed of a plurality of components, such as two separate components,
three separate components, four separate components, five separate
components, and so on. In various embodiments, separate components of the
aerosol precursor composition can be transported by separate wicks or
separate and defined groups of filaments in a single wick. Separate
transport can apply in this regard to each individual component of the
aerosol precursor composition or any combination of the individual
components. For example, a single reservoir can be segmented and
different components of the aerosol precursor composition can be housed
in the different segments for transport by the wick filaments in fluid
connection with the specific segment. Alternatively, different reservoirs
with different wicks combined therewith can be utilized. Various
combinations of one or more reservoirs, one or more transport elements,
and one or more heater elements, all having various designs and formed of
various materials, may be used according to the present disclosure.

[0113] Beneficially, utilizing separate transport of separate components
of the aerosol precursor composition to separate heating elements can
allow for the separate components to be heated to different temperatures
to provide a more consistent aerosol for draw by a user. Although the
aerosolization temperature of separate heaters can be substantially the
same, in some embodiments, the aerosolization temperature of the separate
heaters can differ by 2° C. or greater, 5° C. or greater,
10° C. or greater, 20° C. or greater, 30° C. or
greater, or 50° C. or greater.

[0114] Although a variety of materials for use in a smoking article
according to the present invention have been described above--such as
heaters, batteries, capacitors, switching components, reservoirs,
dispensers, aerosol precursors, and the like, the invention should not be
construed as being limited to only the exemplified embodiments. Rather,
one of skill in the art can recognize based on the present disclosure
similar components in the field that may be interchanged with any
specific component of the present invention. For example, U.S. Pat. No.
5,261,424 to Sprinkel, Jr. discloses piezoelectric sensors that can be
associated with the mouth-end of a device to detect user lip activity
associated with taking a draw and then trigger heating; U.S. Pat. No.
5,372,148 to McCafferty et al. discloses a puff sensor for controlling
energy flow into a heating load array in response to pressure drop
through a mouthpiece; U.S. Pat. No. 5,967,148 to Harris et al. discloses
receptacles in a smoking device that include an identifier that detects a
non-uniformity in infrared transmissivity of an inserted component and a
controller that executes a detection routine as the component is inserted
into the receptacle; U.S. Pat. No. 6,040,560 to Fleischhauer et al.
describes a defined executable power cycle with multiple differential
phases; U.S. Pat. No. 5,934,289 to Watkins et al. discloses
photonic-optronic components; U.S. Pat. No. 5,954,979 to Counts et al.
discloses means for altering draw resistance through a smoking device;
U.S. Pat. No. 6,803,545 to Blake et al. discloses specific battery
configurations for use in smoking devices; U.S. Pat. No. 7,293,565 to
Griffen et al. discloses various charging systems for use with smoking
devices; US 2009/0320863 by Fernando et al. discloses computer
interfacing means for smoking devices to facilitate charging and allow
computer control of the device; US 2010/0163063 by Fernando et al.
discloses identification systems for smoking devices; and WO 2010/003480
by Flick discloses a fluid flow sensing system indicative of a puff in an
aerosol generating system; all of the foregoing disclosures being
incorporated herein by reference in their entireties. Further examples of
components related to electronic aerosol delivery articles and disclosing
materials or components that may be used in the present article include
U.S. Pat. No. 4,735,217 to Gerth et al.; U.S. Pat. No. 5,249,586 to
Morgan et al.; U.S. Pat. No. 5,666,977 to Higgins et al.; U.S. Pat. No.
6,053,176 to Adams et al.; U.S. 6,164,287 to White; U.S. Pat No.
6,196,218 to Voges; U.S. Pat. No. 6,810,883 to Felter et al.; U.S. Pat.
No. 6,854,461 to Nichols; U.S. Pat. No. 7,832,410 to Hon; U.S. Pat. No.
7,513,253 to Kobayashi; U.S. Pat. No. 7,896,006 to Hamano; U.S. Pat. No.
6,772,756 to Shayan; US Pat. Pub. Nos. 2009/0095311, 2006/0196518,
2009/0126745, and 2009/0188490 to Hon; US Pat. Pub. No. 2009/0272379 to
Thorens et al.; US Pat. Pub. Nos. 2009/0260641 and 2009/0260642 to
Monsees et al.; US Pat. Pub. Nos. 2008/0149118 and 2010/0024834 to
Oglesby et al.; US Pat. Pub. No. 2010/0307518 to Wang; and WO 2010/091593
to Hon. A variety of the materials disclosed by the foregoing documents
may be incorporated into the present devices in various embodiments, and
all of the foregoing disclosures are incorporated herein by reference in
their entireties.

[0115] Although an article according to the invention may take on a
variety of embodiments, the use of the article by a consumer will be
similar in scope. In particular, the article can be provided as a single
unit or as a plurality of components that are combined by the consumer
for use and then are dismantled by the consumer thereafter. Generally, a
smoking article according to the invention can comprise a first unit that
is engagable and disengagable with a second unit, the first unit
comprising the resistive heating element, and the second unit comprising
the electrical power source. In some embodiments, the second unit further
can comprise one or more control components that actuate or regulate
current flow from the electrical power source. The first unit can
comprise a distal end that engages the second unit and an opposing,
proximate end that includes a mouthpiece (or simply the mouthend) with an
opening at a proximate end thereof. The first unit can comprise an air
flow path opening into the mouthpiece of the first unit, and the air flow
path can provide for passage of aerosol formed from the resistive heating
element into the mouthpiece. In preferred embodiments, the first unit can
be disposable. Likewise, the second unit can be reusable.

[0116] More specifically, a smoking article according to the invention can
have a reusable control body that is substantially cylindrical in shape
having a connecting end and an opposing, closed end. The closed end of
the control housing may include one or more indicators of active use of
the article. The article further can comprise a cartridge with a
connecting end that engages the connecting end of the control body and
with an opposing, mouthend. To use the article, the consumer can connect
a connecting end of the cartridge to the connecting end of the control
body or otherwise combine the cartridge with the control body so that the
article is operable as discussed herein. In some embodiments, the
connecting ends of the control body and the cartridge can be threaded for
a screw-type engagement. In other embodiments, the connecting ends can
have a press-fit engagement.

[0117] During use, the consumer initiates heating of the resistive heating
element, the heat produced by the resistive heating element aerosolizes
the aerosol precursor composition and, optionally, further inhalable
substances. Such heating releases at least a portion of the aerosol
precursor composition in the form of an aerosol (which can include any
further inhalable substances included therewith), and such aerosol is
provided within a space inside the cartridge that is in fluid
communication with the mouthend of the cartridge. When the consumer
inhales on the mouth end of the cartridge, air is drawn through the
cartridge, and the combination of the drawn air and the aerosol is
inhaled by the consumer as the drawn materials exit the mouth end of the
cartridge (and any optional mouthpiece present) into the mouth of the
consumer. To initiate heating, the consumer may actuate a pushbutton,
capacitive sensor, or similar component that causes the resistive heating
element to receive electrical energy from the battery or other energy
source (such as a capacitor). The electrical energy may be supplied for a
pre-determined length of time or may be manually controlled. Preferably,
flow of electrical energy does not substantially proceed in between puffs
on the article (although energy flow may proceed to maintain a baseline
temperature greater than ambient temperature--e.g., a temperature that
facilitates rapid heating to the active heating temperature).

[0118] In further embodiments, heating may be initiated by the puffing
action of the consumer through use of various sensors, as otherwise
described herein. Once the puff is discontinued, heating will stop or be
reduced. When the consumer has taken a sufficient number of puffs so as
to have released a sufficient amount of the inhalable substance (e.g., an
amount sufficient to equate to a typical smoking experience), the
cartridge can be removed from the control housing and discarded.
Indication that the cartridge is spent (i.e., the aerosol precursor
composition has been substantially removed by the consumer) can be
provided. In some embodiments, a single cartridge can provide more than a
single smoking experience and thus may provide a sufficient content of
aerosol precursor composition to simulate as much as full pack of
conventional cigarettes or even more.

[0119] The foregoing description of use of the article can be applied to
the various embodiments described through minor modifications, which can
be apparent to the person of skill in the art in light of the further
disclosure provided herein. The above description of use, however, is not
intended to limit the use of the inventive article but is provided to
comply with all necessary requirements of disclosure of the present
invention.

[0120] In certain embodiments, a smoking article according to the present
disclosure can be characterized as a disposable article (or as including
a disposable unit--e.g., a disposable cartridge). Accordingly, it can be
desirable for the reservoir containing the aerosol precursor composition
in such embodiments to include a sufficient amount of aerosol precursor
composition so that a consumer can obtain more than a single use of the
article. For example, the article can include sufficient aerosolizable
and/or inhalable materials such that the article can provide a number of
puffs substantially equivalent to the number of puffs (of about two to
four seconds duration) available from a plurality of conventional
cigarettes--e.g., 2 or more, 5 or more, 10 or more, or 20 or more
conventional cigarettes. More particularly, a disposable, single unit
article according to the present disclosure can provide about 20 or more,
about 50 or more, or about 100 or more puffs, a single puff being
measured as otherwise described herein.

[0121] In preferred embodiments, the article can take on a size that is
comparative to a cigarette or cigar shape. Thus, the article may have a
diameter of about 5 mm to about 25 mm, about 5 mm to about 20 mm, about 6
mm to about 15 mm, or about 6 mm to about 10 mm. Such dimension may
particularly correspond to the outer diameter of the shell. In addition
to the foregoing, the control body and cartridge can be characterized in
relation to overall length. For example, the control body can have a
length of about 50 mm to about 110 mm, about 60 mm to about 100 mm, or
about 65 mm to about 95 mm. The cartridge can have a length of about 20
mm to about 60 mm, about 25 mm to about 55 mm, or about 30 mm to about 50
mm. The overall length of the combined cartridge and control body (or the
overall length of a smoking article according to the invention formed of
a single, unitary shell) can be approximately equal to or less than the
length of a typical cigarette--e.g., about 70 mm to about 130 mm, about
80 mm to about 125 mm, or about 90 mm to about 120 mm.

[0122] In specific embodiments, a disposable unit or cartridge according
to the invention can be substantially identical to a cartridge as
described above in relation to the appended figures. Thus, a disposable
cartridge can comprise a substantially tubular shaped cartridge shell
having a distal attachment end configured to engage a reusable smoking
article or medicament delivery article and an opposing mouthend
configured to allow passage of a formed vapor and any further inhalable
materials to a consumer. The cartridge shell can define an interior
cartridge space that includes additional cartridge components,
particularly inwardly and/or outwardly wicking wicks formed of a
plurality of filaments in fluid communication with a reservoir.

[0123] Although the various figures described herein illustrate the
control body and the cartridge in a working relationship, it is
understood that the control body and the cartridge can exist as
individual devices. Accordingly, any discussion otherwise provided herein
in relation to the components in combination also should be understood as
applying to the control body and the cartridge as individual and separate
components.

[0124] In another aspect, the invention can be directed to kits that
provide a variety of components as described herein. For example, a kit
can comprise a control body with one or more cartridges. A kit further
can comprise a control body with one or more charging components. A kit
further can comprise a control body with one or more batteries. A kit
further may comprise a control body with one or more cartridges and one
or more charging components and/or one or more batteries. In further
embodiments, a kit may comprise a plurality of cartridges. A kit further
may comprise a plurality of cartridges and one or more batteries and/or
one or more charging components. The inventive kits further can include a
case (or other packaging, carrying, or storage component) that
accommodates one or more of the further kit components. The case could be
a reusable hard or soft container. Further, the case could be simply a
box or other packaging structure.

[0125] Many modifications and other embodiments of the invention will come
to mind to one skilled in the art to which this invention pertains having
the benefit of the teachings presented in the foregoing descriptions and
the associated drawings. Therefore, it is to be understood that the
invention is not to be limited to the specific embodiments disclosed
herein and that modifications and other embodiments are intended to be
included within the scope of the appended claims. Although specific terms
are employed herein, they are used in a generic and descriptive sense
only and not for purposes of limitation.

Patent applications by Andries Don Sebastian, Clemmons, NC US

Patent applications by David William Griffith, Jr., Winston-Salem, NC US

Patent applications by Grady Lance Dooly, Winston-Salem, NC US

Patent applications by Stephen Benson Sears, Siler City, NC US

Patent applications by Yi-Ping Chang, Greensboro, NC US

Patent applications by R.J. Reynolds Tobacco Company

Patent applications in class MAKING OR USING TOBACCO USERS' APPLIANCE

Patent applications in all subclasses MAKING OR USING TOBACCO USERS' APPLIANCE